Factory Assembly Systems

Catalogue 2006 / 2007

Technologies . Systems . Solutions

Issue date 01.09.2006

We reserve the right of technical
changes in the course of continous
developement of our products
Layout & Realization:
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www.awiwa.de

Factory
Assembly
Systems

Catalogue 2006 / 2007

Technologies . Systems . Solutions

1

Factory Assembly Systems FAS

As an international partner of

Our customers requirements

Our main aim is to perpetually

the automotive industry Drr

are the main focus of our activi-

open new possibilities for our

stands for leading edge techno-

ties when working out optimal

customers, to reduce their costs

logy, high quality and customer

process solutions and choosing

per unit and to increase their

proximity.

suitable products in cooperation.

competitiveness.

With the business unit Factory

To do this, we draw upon a

Assembly Systems (FAS) Drr

comprehensive base of know-

FAStplant the modular way

takes also a leading position

ledge and experience resulting

of erecting, dismantling and

within vehicles final assembly

from customer relations with

modifying a complete assembly

and delivers high-end conveyor

nearly all automobile manufac-

line is only one example for

technology, products and systems

turers worldwide, ranging from

innovation made by Factory

for assembly processes in the

mass production to up-market

Assembly Systems.

automotive industry.

production or from compact car

makers to light truck makers.

solutions Drr FAS is optimally

Our portfolio of products and

services is based on extensive

From planning through to deli-

positioned to meet the demands

process competence which

very and service, FAS accom-

that the assembly of future-

translates into our products and

panies the entire life cycle of a

oriented and cost-conscious

which in turn allow FAS to cover

project. Our portfolio ranges

automotive plants brings.

more than 70 % of the total

from minute items of equip-

investment for equipment

ment to turn-key delivery of

required in a final assembly plant

entire assembly shops.

from in-house manufacture.

Included are products such as

With production sites on three

marriage systems, axle assembly,

continents and a most profes-

filling systems, all kinds of con-

sional project management we

veyors, complete end-of-line

consistently produce high quality

equipment, glazing systems and

products and ensure schedule

handling equipment.

and budget adherence.

Our strength of innovation
results from our high process
competence. Thus, we are setting on intensive development
activities in all fields.

Technologies, systems and

Contents

Factory Assembly Systems FAS 2

Conveyor Systems : : : : : : : : : : 4
Survey/ System Elements : : : : : : : : : : : : 6 -

Overhead Conveyors FAStrolley : : : : : : 10 - 17

Floor Conveyors FASfloor : : : : : : : : : : : 18 - 29

Final Assembly : : : : : : : : : : : : 30
Fluid Filling FASprofill : : : : : : : : : : : : : : 32 - 41
Assembly Equipment FASsembly : : : : 42 - 63

Testing Systems FAStest : : : :64

Wheel Alignment : : : : : : : : : : : : : : : : : 66 - 75
Headlight Aiming : : : : : : : : : : : : : : : : : 76 - 81
Driver Assistance Systems Testing : : : 82 - 85
End of Line Function Test : : : : : : : : : : : 86 - 95
In-Line Testing : : : : : : : : : : : : : : : : : : : 96 - 103

Automation : : : : : : : : : : : : : : 104
Survey : : : : : : : : : : : : : : : : : : : : : : : : 106 - 107
Basic Software and Components : : : 108 - 109

Elektronics Testing and

Server Systems FAStronic : : 110
Survey : : : : : : : : : : : : : : : : : : : : : : : : 112 - 113
Server Systems : : : : : : : : : : : : : : : : : 114 - 121
Test Stations : : : : : : : : : : : : : : : : : : : : 122 - 125
Mobile Diagnostic Systems : : : : : : : : 126 - 133
Measurement Systems : : : : : : : : : : : :134 - 137
Accessoires : : : : : : : : : : : : : : : : : : : : :138 - 141

Advanced Factory Solutions 142

Survey : : : : : : : : : : : : : : : : : : : : : : : : 144 - 145
Planning : : : : : : : : : : : : : : : : : : : : : : : 146 - 153
Cross Functions : : : : : : : : : : : : : : : : : 154 - 157
FAScontract : : : : : : : : : : : : : : : : : : : : 158 - 167

DRR Worldwide : : : : : : : : : : 168

Conveyor Systems

Survey : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 6 - 7
System Elements : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 8 - 9

Overhead Conveyors FAStrolley

Power & Free : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 10 - 11
Electric Monorail System : : : : : : : : : : : : : : : : : : : : : : : : : : 12 - 13
Twin Trolley System (TTS) : : : : : : : : : : : : : : : : : : : : : : : : : 14 - 15
Vertical Adjusting Conveyor : : : : : : : : : : : : : : : : : : : : : : : : : 16 - 17

Floor Conveyors FASfloor

Skid Conveyor : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 18 - 19
Twin Trolley System (TTS Inverted) : : : : : : : : : : : : : : : : : : 20 - 21
FASmatic : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 22 - 23
Skillet Conveyor : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 24 - 25
Belt Conveyor / Modular Chain Conveyor

: : : : : : : : : : : : : 26 - 27

Slat Conveyor : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 28 - 29

Drr conveyor systems:

Innovative efficient
and user-oriented
Just in time or just in se-

In view of increasing demands

quence Drr conveyor systems

for the reliability of a plant verti-

from the Factory Assembly

cal adjustment conveyors with

Systems business unit meet all

modern belt technique and

requirements for more flexibility

water resisting modular chain

and cost effectiveness. We set

conveyors form an important

standards in respect of functio-

part of our portfolio.

nality and innovations with our

extensive range of floor conveyors

Against the background of high-

and overhead conveyors. We

quality demands we conse-

offer maximum reliability with

quently improve our range of

reduced maintenance effort.

products.

Two examples are our patented

innovation Twin Trolley System

The market success of Drr FAS

(TTS) with its modular structure

is the result of a continuous

and

FASmatic,

the automatic

systems and the fulfilment of

system for non-contact energy

specific customer demands.

and data supply, can be in-stalled

with almost all conveyor technologies. Thus, Drr FAS continues
with setting new standards for
higher availability and less maintenance.

development of our conveyor

guided vehicle. FASmotion, our

Conveyor Systems
Survey

Your Advantage

The Conveyor Systems

Overhead conveyors
FAStrolley

Floor conveyors
FASfloor

High reliability
Low maintenance effort

Power&Free

Skid conveyor

Electric Monorail System

TTS inverted

Twin Trolley System (TTS)

FASmatic

Vertical Adjustment
Conveyor

Skillet conveyor

Future-proof thanks to
standardized product range
Non-contact energy and
data transfer optional

Belt conveyor /
Modular chain conveyor
Slat conveyor

Twin Trolley System (TTS)

In this new technology, the drives are not accommodated in
the trolleys but in the rail. This means that no on-board control
is required. In a further development, TTS is combined with
the Skillet technique.

Electric Monorail System (EMS)

Equally suited to use on pure conveying sections at
high speed and on work lines with adjustable speed.
Further strength of EMS is its quiet and
clean operation.

Vertical Adjusting Conveyor

Vertical Adjusting Conveyors by Drr stand for precise adjusting
of height and maximum functionality. Its innovative belt technique allows minimized maintenance effort.

Power & Free

Exceedingly rugged and simple chain conveyors.
The scope of application of this conveyor comes to the fore
primarily where machining or processing operations do not
coincide timewise with materials flow.

Slat Conveyors
The convincing features of this conveyor are its
rugged chain drive and its high resistance to moisture,
dirt and high temperatures.

Conveyor Systems
System Elements

FASmatic
FASmatic is controlled by a high-capacity supervisory system
and operates with inductive energy and data transfer. On-board
batteries and pits are no more necessary and changes in the layout can be executed with minimized effort.

TTS inverted
TTS inverted is the floor guided version of the Drr innovation
Twin Trolley System (TTS). The form-fitting drive system
joins very high acceleration and exact positioning with
minimized spare parts.

Skillet
Skillets, optionally with integrated lifting device, allow an optimum
working level for each section. In touch with state-of-the-art part
logistics, it sets up the backbone of innovative "just in sequence"
production.

Belt Conveyor / Modular Chain Conveyor

As man movers and for vehicle body conveying, belt conveyors
are popular in final assembly. The modular chain conveyor is a
further development of the belt conveyor. It is insensitive against
dirt and requires low maintenance effort.

Skid Conveyor
Plant layouts in body, paint and final assembly shops
are no problem with skid conveyors. Thanks to modular design,
all material flow functions can be built in a flexible manner.

F A S t r o l l e y
10

Technical Data and Dimensions

Overall size 4

Overall size 6

Chain pitch

Ultimate load

approx. 220 000 N

approx. 440 000 N

Conveying speed (standard)

0.5 - 18 m/min

0.5 - 18 m/min

Horizontal curves

15 - 180

15 - 180

Vertical curves

10 - 35

10 - 35

Max. payload capacity, double trolley

approx. 2,000 kg

approx. 2,400 kg

Higher payload capacities with multiple trolley possible

Overhead Conveyors
FAStrolley
Power & Free

System Elements
Rail system, including
suspension, consisting of
Power & Free rail in
size 4and 6
Chain, including pusher dogs
Horizontal curves
Vertical curves
Transfers
Trolleys
Power & Free systems can be

Owing to the simple, modular

used both as overhead con-

design, it is possible to imple-

veyor systems and as floor con-

ment different functions, such

veyor systems (inverted P & F).

as buffering, distribution, bran-

In the automotive industry,

ching or stopping very easily

P & F conveyors are used for

and at low cost.

in-plant transport in all sectors

P & F systems are very rugged

from the body shop through the

and can be used easily even

paint shop to final assembly.

under aggravated ambient

Standardized components of

conditions, such as high tem-

various sizes are available for

peratures or aggressive media

various loads.

or in welding lines.

Drive station
Tensioning station
Switches
Stoppers
Lifting stations
Control system

Mode of Operation
A Power & Free system
consists of two rails arranged one above the other.
A chain runs continuously
in the upper rail (power
rail) and this chain pulls
the trolleys in the lower
free rail by means of
dog pushers. The bogies
can be engaged and
disengaged as required.

11

F A S t r o l l e y
12

Technical Data and System Elements

EMS Light
VDI 500

EMS Medium

EMS Heavy-duty

Aluminum profile
(rail)

180 x 60 mm

180 x 60 mm

240 x 80 mm

Payload capacity
(hanger + load)

500 kg /trolley

750 kg /trolley

1,800 kg /trolley

Transport
speed

up to 120 m/min

80 m/min

40 m/min

Curves

Switches

Track lengh

15/30/45/90
15/30/45/90
15/30/45/90
in the case of radius 1,000 and 1,500 mm
45 in the case of radius 750 mm
Optional rotary switches
unlimited

unlimited

45 in the case of
radius 1,000 mm
unlimited

Overhead Conveyors
FAStrolley
Electric Monorail System

System Elements
Rail, including energy
supply (busbar
or FASmotion)
Single trolley
Double trolley
On-board control
Horizontal curves
Vertical curves
Lifting stations
The electric monorail system

EMS Medium

(EMS) is a modular-design over-

up to 750 kg payload

head conveyor system for trans-

capacity per trolley:

porting complete vehicles or ve-

This version is used to trans-

hicle bodies and also all pos-

port bodies in white and heavy

sible attachments, such as doors,

components. The principal di-

cockpits or seats. The principal

mensions of the aluminum pro-

dimensions are standardized in-

file are 180 x 60 mm.

Switches
Hanger (with / without lift)

Field of Application
Vehicle body transport

ternationally. This system offers

all capabilities of line routing

EMS Heavy-duty

through an installation. It is also

up to 1,800 kg payload

possible to easily implement

capacity per trolley:

buffer functions, distribution

This version is used to trans-

functions and branch functions.

port vehicle bodies in the area

We are able to supply two ver-

of vehicle final assembly.

sions of electric monorail system.

The principal dimensions of

Transport of miscellaneous
hardware and attachments,
such as doors, cockpits and
engines etc.

the aluminum profile are 240 x

EMS Light with

80 mm.

500 kg payload capacity

per trolley:
This version is used primarily for
transporting attachments such
as doors and cockpit and for powertrain components such as
axles and engines. The dimensions of the aluminum profile are
based on the VDI 3643 Regulation.

13

F A S t r o l l e y
14

TTS - Light

TTS - Heavy

TTS - Skillet

Field of Application

Field of Application

Field of Application

Transport of components,

Transport of vehicle bodies,

Combination of TTS with

such as cockpits, doors and

e.g. in final assembly

skillet system. Used, for

powertrain components

instance, on work lines

in final assembly
Transportation is performed
using TTS Heavy outside of
the work lines

Technical Data and Dimensions

Type

TTS - Light

TTS - Heavy

TTS - Skillet

Payload capacity (hanger + load)

600 kg/2 trolleys

2,500 kg/2 trolleys

5,000 kg/4 trolleys

2,500 kg/2 trolleys

5,000 kg/4 trolleys

Conveying speed
on straight sections

up to 150 m/min

max. 40 m/min

3 - 7.5 m/min

Conveying speed in curves

max. 30 m/min

max. 24 m/min

Overhead Conveyors
FAStrolley
Twin Trolley System

Basic elements
Straight section

Horizontal curve

The innovative Twin Trolley

appreciable wear. Provided

System

with flexible hanger, the vehicle

(TTS) with its modular

drive concept overcomes

bodies can be lowered to any

upgrade sections without the

working height. It is also pos-

need for additional installations.

sible to operate with an over-

We can thus implement high

head skillet line in the further

speeds with no slip and no

development, the Skillet TTS.

Vertical curve

System Elements
Type

TTS - Light

TTS - Heavy

TTS - Skillet

Straight rail section

4/5/6/7/8 meters

4/5/6/7/8 meters

4/5/6/7/8 meters

Curves

15/30/45/90
at radius of 600 mm

15/30/45/90 at
radius of 1,500 mm

Upgrade/downgrade section max. 30

max. 20

Switches

30/45/90 at
radius of 1,500 mm

30/45/90
at radius of 600 mm

Rail profile material (straight Aluminum

section / curve / switch)
extruded profile

Aluminum
extruded profile

Aluminum
extruded profile

Track lengths

unlimited

with 1 push drive

36-84 m, longer
lengths on request

unlimited

Switch

Options
Lifters
Hanger (with / without lift)

Preferred values in bold

15

F A S t r o l l e y
16

Technical Data
Type

Single scissors

Double scissors

Stroke

up to 2,500 mm

up to 4,500 mm

Payload (car body)

3,000 kg

3,000 kg

Lifting velocity

max. 10 m/min

max. 10 m/min

Overhead Conveyors
FAStrolley
Vertical Adjusting Conveyor

System Elements
Overhead conveyors
(EMS or TTS)
Energy- and data transfer
(non-contact with
FASmotion or
with bus bar)
Upper frame with drive
and safety equipment
Lifting belts with integrated
steel cables
Lift scissors
Subframe
Load carrying equipment
(C, T or 4-arm-hangers)

Field of Application
Overhead conveyor with
vertical adjustment in BIW
paint and final assembly

With monorail and twin trolley

Both continuous and intermit-

systems, vertically adjustable

tent ope-rations are possible.

conveyor hangers can be used

The application of belt techni-

from the body shop right through

que reduces the maintenance

to the final assembly shop. Their

requirements substantially.

standardized modular design

allows adjusting the height to
the desired position and also
meets high ergonomic requirements. The goods to be transported are loaded and unloaded
by adjacent conveyors.

17

F A S f l o o r
18

Technical Data and Dimensions

Standard

Options

Payload (skid+car body)

700/1,400/2,000 kg

Skid length

4,800 mm

3,400 7,000 mm

Transfer rate

60 units/h

on request
till max. 100 units/h

Track

900 mm

650 1,150 mm

Conveying height

500 mm

on request

Roller pitch

1,064 mm

864 / 1,264 mm

Conveying velocity

24 m/min

on request
till max. 100 m/min

Floor Conveyors FASfloor

Skid Conveyor

System Elements
Roller bed
Excenter lift table
Turn- / pivot table
Transfer car
Lifter for normal- und
high temperature area
Scissors lifting table
(hydraulics, belt, spindle)
Skid stacker
Skid locking unit
Transversal belt / chain
Buffer belt / chain
Suspension belt / chain
Process conveyor
through spray booth
Process conveyor
through oven (up to 220 C)
RoDip
Pendulum conveyor
Skid conveyors are modular con-

Drr offers pre-mounted, pre-

veyors customized to meet indi-

installed and tested mechatronic

vidual needs in body, paint and

systems fitted with belts in the

final assembly shops. Standar-

normal temperature range (no

dized mechanical and electrical

lubrication, thus low mainten-

systems using identical compo-

ance requirements), and fitted

nents permit keeping a reduced

with chains in the high tempera-

number of spare parts in stock

ture range (up to 220 C). Thanks

at maximum reliability ( 99.5 %).

to modular design, all material

Continuous and intermittent

flow functions such as buffers

operations are possible.

and distribution systems can be

built in a flexible manner.

UBS-Shuttle

Field of Application
Skid conveyors for bodyshop,
paint and final assembly
Application in high temperature area
Application in wet area
Application in ex-area

19

F A S f l o o r
20

Technical Data

Payload
(tooling plate + work piece)

700 kg

Conveying velocity
on straight sections

till 100 m/min

Conveying velocity
in curves

max. 30 m/min

Horizontal curve

Radius = 1,000 mm

Vertical curve

Radius = 2,000 mm

Floor Conveyors FASfloor

Twin Trolley System
TTS Inverted

Basic elements
Straight section

Horizontal curve

The compact design of the Inver-

the range and number of spare

ted TTS conveyor system offers

parts that have to be kept in

good body accessibility and the

stock. In addition, the skillet ver-

incorporation of a toothed belt

sion of this system has the advan-

drive ensures exact positioning.

tage of needing fewer drive units.

Vertical curve

The high acceleration that is possible with an Inverted TTS makes

it an ideal system for shuttle

Switch

applications. Using identical technology for both overhead and

floor conveyors reduces the number of different conveyor systems
required and this in turn reduces
Field of Application
Floor conveyor in body shop,
paint shop and final assembly
Continuous and intermittent
operations are possible
For operation in demanding
environmental conditions
(dirt, temperature), the
toothed belt can be replaced
by chain

21

F A S f l o o r
22

Technical Data
Chassis- and
steering concept

Payload (incl.
tooling plate)
Running velocity
Energy transfer
Line guidance
Vehicle communication
Superstructure

Track length
References

4-wheel-concept
Single wheel-steering
front + back

4-wheel-concept
Center pivote platesteering front + back

till 3,500 kg

till 60 m / min
FASmotion (non-contact)
inductive (non-contact)
via funk (WLAN)
scissors lifting table, lifting device,
tooling fixture
unlimited
VW Mosel (Golf A5)
VW Mosel (Passat B6)

BMW Leipzig, S-GM Shanghai

MBUSI Tuscaloosa, KIA Zilina

Floor Conveyors FASfloor

FASmatic

System Elements
Floor installation
Stationary control
Vehicle underframe
with steering concept
Lifting unit
Tooling fixture (swimming
function optional)
Energy transfer
FASmotion
Line guidance
Data transfer
Safety equipment
Onboard control

Field of Application
Floor conveying in
discrete manufacturing
Dress-up area
Unit assembly / fitting
Sub-assembly conveying
FASmatic is a new floor con-

designed freely, pits are no more

veyor system which is mainly

necessary. In energy supply, non-

used in discrete manufacturing

contact energy transfer FAS-

for dress-up stations and the

motion does replace batteries.

marriage process in general

This ensures trouble-free conti-

assembly. It is applicable in con-

nuous operation with high availa-

tinuous flow as well as in stop

bility and low maintenance effort.

and go-operation and offers

free access from all sides. Its
modular control system is an
open concept composed of
standardized components. The
layout of plant and path can be

23

F A S f l o o r
24

Technical Data and Dimensions

Payload capacity

2,500 kg (vehicle body)

Conveying speed

0.5 7.5 m/min. (adjustable)

Useful stroke of lifting table

approx. 1,000 mm

Dimensions

Length approx. 6,000 mm

Width approx. 3,000 mm
Other dimensions on request

Floor Conveyors FASfloor

Skillet Conveyor

System Elements
Skillets with/ without
lifting table
Lifting tables hydraulic/
with spindle/with belt
Track
Power supply busbar/
non-contact energy
and data transfer
FASmotion
Main drive based on friction wheel
Docking and undocking drives
Roller beds
Cross conveyors
Lifters

This system is used in the sec-

an optimum working position.

The skillets may also be moved

tors of vehicle final assembly

The skillet can be powered via

on roller beds, lifters and cross

and body shop.

conventional busbars or also

conveyors outside of the actual

The skillets are suitable for foot

using non-contact energy and

skillet lines.

traffic and may be equipped

data transfer FASmotion.

with various superstructures

Besides the actual skillets, a

for accommodating the vehicle

skillet line contains the following

bodies. If eccentric lifting tables

chief components: docking

are used, the working height

drive, main drive, braking drive,

of the vehicle body can be ad-

undocking drive and roller strips

justed variably so as to ensure

on which the skillets lie.

25

F A S f l o o r
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Technical Data
Skid
cross conveying

Man mover

Vehicle
conveying

Vehicle conveying
special applications

Case of
operation

Cross conveying
for Skid in bodyshell
work, paint and
final assembly

Conveying
of men

Conveying of
vehicles on
wheels

Conveying of
vehicles on wheels
through leak test

Distance
between axles

Standard till 15m

Standard till 100m

Standard till 100m

Standard till 100m

Payload

700/1,400/2,000 kg
skid + workpiece

400 kg
on 6m length

3,000 kg
on 6m length

3,000 kg
on 6m length

Transportvelocity

4 till 20m/min

0.5 till 10m/min

0.5 till 10m/min

0.5 till 10m/min

Width

1,400kg 2x100mm
2,000kg 2x200mm

maximal 4m

maximal 4m

maximal 4m

Floor Conveyors FASfloor

Belt Conveyor /
Modular Chain Conveyor

System Elements
Base frame with track
Modular chain conveyor
Drive unit
Deflection unit,
if applicable
with braking drive
Drive
unit

A distinction is made in the

Basically, there are two types:

Deflection unit

Drive

Base frame
with track

case of belt conveyors and modular chain conveyors in the

Type 1:

sector of vehicle transport bet-

Wide belt with a width of

ween man movers and con-

approx. 1 to 4 m for transporting

veyor belts for vehicle body

vehicle body and, if applicable,

transport.

worker.

Man movers:

Type 2:

These are normally 1 to 4 m-

Twin-strand belt with a width

wide belts on which the wor-

of approx. 300 500 mm.

Field of Application
Skid conveying
Man mover

kers ride at the same process

speed as the main line. The

Modular chain conveyors are a

vehicle body is transported

low cost alternate to slat and

in an overhead conveyor for

belt conveyors as it is possible

instance while the worker rides

to replace single modules, and

on a man mover below the

their low structure calls for far

vehicle body at the same speed

smaller pit dimensions. In con-

as the vehicle body itself.

trast to belt conveyors, these

Overhead operations can be

conveyors are driven by form-fit

configured ergonomically with

connection and not by friction.

this arrangement.

Since it is not necessary to

Vehicle body conveying

Vehicle body conveying
through leak test

weld belts on site, maintenance

Vehicle body transport:

requirements, wear and tear

The vehicle bodies are normally

are notably lower than with

transported with their wheels

conventional belt conveyors.

on the belt or the modular chain.

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F A S f l o o r
28

Technical Data and Dimensions

Distance between axles

up to 200 m

Payload capacity

approx. 3,000 kg over 6 m length

Transport speed

1 7.5 m/min.

Width

Double-strand version approx. 300 500 mm

Single-strand version approx. 3,000 mm

Floor Conveyors FASfloor

Slat Conveyor

System Elements
Chain with slats
Base frame
Drive unit
Deflection and tensioning unit

Field of Application
Transporting vehicle bodies
Transporting vehicle bodies
in the wet area
(leak test)

On slat conveyors, vehicle bodies are transported through

the body shop or vehicles are
transported through final assembly. Owing to the rugged
chain drive and the high resistance to moisture and dirt, this
system is ideally suited to welding areas in the body shop, the
car final area and leak test in
vehicle final assembly.

29