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Electric Car Battery Cell Assembly Line

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The assembly line of Cell for Electric Car Batteries is a turnkey Project integrated in automatic cycle with one injection moulding press to produce the complete co-moulded modular cell then composing the electric car battery.

Starting from the aluminium coils and the raw plastic feeding to the press, it automatically performs the operations of aluminium cells forming and blanking, transfer to the assembly lines, handling, orientation and insertion into the injection mould, unloading of the cells, quality controls, orientation, loading of trays and stacking of the trays to form the final pallet, ready to be shipped to the End user.

Cycle time: 35 sec/12 pcs (multi-cavity moulding cycle of 12 cells).

Production and control operations:

  • Forming and blanking of aluminium cells starting from coils.
  • Quality control of the aluminium cells with dedicated camera.
  • Buffer station of aluminium cells, fed by the production line, to allow production continuity at coils change.
  • Transfer, handling and orientation of the aluminium cells with electric units and shuttles.
  • High-rigidity cartesian robot with two units to load 6 aluminium cells each into the mould and unload 6 finished cells each from the mould.
  • Orientation and transfer to the quality control and dummy stations.
  • Vision systems to control the correct injection, the cleanliness of the aluminium surfaces – plates and wings without plastic scraps – and the presence and depths of holes.
  • Cartesian robot equipped with special dedicated multi-picking units to load the finished cells to the tray laying on a deposit station, transfer the full tray to the pallet being formed and load the empty tray to the deposit station.
  • Automatic conveyor chain to move the empty and full pallets.

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Gas Springs Assembly Line Icona Pdf

The line automatically performs assembly and palletizing operations of gas springs, connecting in an integrated workflow a range of Products with different components configuration features and variable dimensions in terms of diameter and length.

The change of batch between different models is managed with no need of any set up; the components’  identification and control at entering the line lead to of the automatic calibration of tools and working stations along the line.

The application uses several different automation and control technologies, specifically integrated and customized to the functional and production time targets.

Steel bushings, stems and cylindric bodies of the Product are fed through dedicated dynamic warehouses, controlled and assembled with the relevant components before entering the main line.

The main line is made of different working stations, fed by a Cartesian axes transfer system up to the final palletizing of the Products into dedicated boxes.

Assembly and control operations:

  • Dynamic warehouses for bushing, stem and cylinder body feeding, with consistency control of all components entering the line;
  • Automatic feeding, robot screwing and control of valves and plugs on the main body;
  • Automatic laser marking and Datamatrix reading for system supervision and traceability;
  • Cartesian axes main line to transfer the components along the different working stations for assembly, control and palletizing;
  • Automatic grease dosing with controlled axes for the different components;
  • Automatic and controlled press fitting with automatic tools change;
  • Automatic gas filling unit with control;
  • Automatic feeding, control, orientation and insertion of plastic markers of different diameter;
  • Automatic palletizing and pallets transfer at the end of the line.

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Automotive Shifter Assembly LineIcona Pdf

The assembly line for automotive Shifter – manual and automatic version – performs several different operations of assembling and control managed by operators in charge of each working station.

The workstations provide guided management of the picking of pieces from the slave warehouses through pick to light systems, a controlled process flow, the manual positioning in poka-yoke dedicated fixture of the components (all controlled by sensors) the start of the automatic assembly and control cycles in full safety.

Working orders are transferred from the IT central system connected to the line with bidirectional communication through a supervisor PC.

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Insert-Moulded Functional Subgroups Assembly Island Icona Pdf

The Functional Insert-Moulded Subgroups Assembly Island is integrated in an automatic cycle with an injection moulding press, equipped with its own handling system for press loading/unloading. It automatically performs operations of handling, assembling, control, laser marking and final unloading of functional insert-moulded subgroups.

An anthropomorphic robot feeds the dedicated deposits with steel components to be inserted by the press handling system in the mould at a set high temperature.

At the end of the pressing process the line receives from the press handling system, into dedicated seats, the insert-moulded Products.

The robot, equipped with specially designed multiple picking hand, transfers the Products to a rotary table; in the table working stations the quality of the moulding is controlled (plastic wings presence), plastic safety rings and metal screws are automatically fed and inserted into the Products, the parts are laser marked, identified with Datamatrix reading and finally unloaded into a motorized belt.

NOK parts are unloaded separately in proper boxes.

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Automotive Subgroups Assembly Island Icona Pdf

The island automatically performs assembly, control, marking and unloading into dedicated boxes of automotive gears units functional subgroups, managing and controlling the different combinations of the components in accordance with the production batch.

The application uses several different automation and control technologies, specifically integrated and customized to the functional and production time targets; overall dimensions are fitting a limited available space.

The production batch of every component is identified by a barcode reader.

Components are automatically fed, the distinctive dimensions (inner and outer diameters, length, colour) are controlled, OK parts are loaded into high precision dedicated seats positioned on a rotary ring.

The use of a rotary ring table grants high precision and speed performances and an optimal efficient distribution of the working stations.

The ring working stations perform the insertion of a metal bushing, the press fitting of a plastic insert into the bushing, the insertion of a plastic sleeve and the edging of the bushing to complete the assembly, the rotation test of the sleeve, the marking of OK parts and their final unloading into boxes.

NOK parts are separately unloaded in every working station.  Watch Video.

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14 + 3 =