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Automation and Testing

Our site in Velbert offers the whole process chain from project planning to the building of automation units, special machinery, gauging and testing - all designed in accordance with your special requirements and product characteristics.



  • Project planning
  • Construction
  • Electrical Planning
  • Fabrication and Assembly
  • Control engineering
  • Software development
  • Commissioning
  • Service and maintenance

              Project Planning
              Consider - plan - design - implement:

              At these stages our Project Teams work together with you to produce economically viable automation solutions - right from the initial beginnings of a solution right through to commissioning the unit on site at its destination. Assembly units with an overall length of up to 70m are possible. We advise and propose solutions aimed at offering you the best possible utilisation for your machine or unit (process and time optimised) at a good price. At the start of a project we put together a team from every special area which aims to produce an optimal result based on your special requirements. 

              All services in one go:

              • Mechanical and electric design
              • Assembly, construction of control systems and electro installation
              • Software development and process optimisation
              • Commissioning at destination
              • Maintenance and service



              The design department is made up of engineers and technicians with many years‘ experience. By using 3D-CAD systems and corresponding interfaces for true data formats, it is possible to work together with our customers on detailed drafts even at the project-planning phase which are eventually included in the subsequent equipment design.

              Through a modular system of design components which is constantly increasing, we are able to place focus in the design on complex solutions for the customer and to achieve very short process time.

              Electrical Design
              The basic pre-requisite for the increasing requirement to automate complex specialist machines is good software planning which has been well thought-through. As well as SPS control concepts, we are just starting to specialise in the sector covering PC-supported control systems.

              Electrics are designed as per customer requirements using ePLAN or E-CAD software such as TreeCAD.




              Production and Assembly
              Because of the constantly changing tasks required in the construction of special-purpose machines, our expert staff have acquired extensive experience which stands us in good steam when assembling and commissioning. The The ground plan of our building allows us to build machines which are 70m long.

              Construction of control systems
              We work closely with our electrical designers to introduce the control system concepts which have been developed. This includes building the control cabinet and the electrical integration of the external control components. Our switchboard units of course comply fully with all standards within the context of CE-identification and are tested and documented in accordance with valid VDE and EN standards.

              Software Development
              A good machine stands out not least because off well thought-out software. Our Software Development Team is made up of programmers who are experienced in the automated sector. The software solutions are implemented as per requirements using PC, SPS or micro-control systems.



              Amongst others, the extensive range includes robotics, image processing, carrier logistics, recording of operational data and control systems, production of software tools for testing and gauging, transponder technology and recording of read-outs and data base programming.

              Commissioning the units takes place with the whole Project Team working very closely together. At this stage, the equipment concept is checked in detail for optimisation potential and partially adjusted. Once the individual stations have undergone a trial run, the whole unit is fatigue-tested before it is shown to the customer for their initial inspection. After successful inspection your unit is transported to your premises and put into operation on site.

              Service and Maintenance
              Our Service Team work closely with our special departments to ensure that any malfunction is eliminated. Any spares required are obtained quickly. We also offer maintenance contracts which have been discussed and agreed with our customers



              Robot-Assisted Systems

              In this application, a six-spindle robot linked to a vision system takes plastic housings of various geometries from bulk separation and moves them into position on a workpiece carrier for further processing.

              In the production of high-end electronic car keys, the individual components are moved by vibratory conveyors and very compact stack storage with three robots, and joined on a round plate. All process steps and events are captured and visualized by Huf Tools production data acquisition and sent to on the network the line server for evaluation.

              Automated Assembly Lines

              This fully automated system is used for the manufacture of several different types of radio car key inserts. All palletizing cells [3 MB] include precision handling systems for assembly and joining.

              The supply contained can be replenished at any time without interrupting automatic assembly of the key inserts on the line. Assembly takes place on workpiece carriers. Relevant information is written to the transponders on the workpiece carriers at each assembly station, so that the status is updated from assembly station to assembly station. If the data on a workpiece reads out as not OK, the fault or faults are categorized as reparable or irreparable. A control computer archives the line data and product test data.
              Assembly line for car door locks with multiple components and number of variants with short cycle times. The line has 8 automated stations and 14 semiautomatic workstations with various functions, including parts supply, bolting, greasing, joining, riveting, mechanical and electrical function testing, and laser lettering.

              Integration of Identification Systems for Conveyor Control

              In complex conveyor systems the parameters for each product and production process can be stored for evaluation and analysis of product-specific test and measurement data.

              To do this, conveyor systems are fitted with our identification system, which also provides conveyor control. There is a transponder on each product carrier to record data. Each station has a read/write unit and an antenna on the conveyor for writing data to the product carrier transponder.

              Testing equipment

              Integration measurement instruments
              The increasing requirements for mechanical and electronic product function quality place high demands on the design of test and production systems. This in turn necessitates the use of special instruments to measure:

              • Length
              • Force
              • Torque
              • Current / voltage / resistance
              • Radio frequency and power
              • Inductivity and coil quality
              • Light intensity



              Testing and measuring these and other dimensions are another core competence of Huf Tools.

              Camera-Assisted Recognition Systems

              Camera-assisted recognition systems use the many possibilities of image processing to detect the position and nature of components, and also measure and sort them according to defined criteria. In the assembly of worm gears in electronic ignition lock housings (ELV), the individual gears are delivered in blisters and supplied to the production line by a compact stack storage system. A camera on the robot detects the position and rotary position of the worm gear and transfers the coordinates to the robot controller for correct positioning.



              Special Machines

              Assembly unit for key production

              As well as automatic sort and feed technology, the fully automatic production of transponder keys also includes a monitored dispensing of adhesive and transpondern programming. The finished products are also checked for the required quality attributes and sorted accordingly.



              Machines for "precision machining" of steel parts

              This circular unit is used for precision machining of steel parts with a 64 Rockwell hardness used for the VW pump nozzle injection moulding system. 

              At the individual stations the transitions between drilled holes, edges and end faces receive a defined fillet radius tolerated to microns. Four parts are machined simultaneously at each brush position. The wear on each brush is monitored and readjusted automatically. The steel parts are machined using oil cooling. The oil is siphoned off completely before the parts are removed.


              Laser inscription units
              Laser technology is being increasingly used in product identification. Our laser inscription units cover the whole spectrum such as marking the car key with the remote authorisation ID or button actuating symbols, inscribing data matrix codes and individual company logos on components.



              Stack Storage

              The provision of components plays an important role in the automation of assembly processes. Vibratory conveyors are usually used for items supplied in bulk. Sensitive parts and parts that must be protected from ESD such as PCBs are supplied in blisters or trays. We have developed our own patent-applied palette and stack storage system that enables loading and unloading of the magazine without interrupting the automated procedure. There is one magazine each for filling with full blisters and removing empties. A rotary drive quickly and accurately moves the blisters into and out of the action area.

              We will be glad to supply detailed information on features, function and performance upon request.

              The palette can be switched out in just 3.2 seconds while the robot handles the parts. Robots with various motion profiles permit the stack storage module to be connected to both round and linear machines. Its ESD-compliant design allows it to be used anywhere.

              Full and empty trays can be switched on the fly without halting the production process. Furthermore, rigorous “first in / first out” handling ensures traceability of parts that require documentation.

              Key Cutting Machines

              As one of the leading manufacturers of electronic and mechanical locking systems for the automotive industry, Huf Hülsbeck & Fürst GmbH & Co KG, with its production sites, is represented all over the world. As a manufacturer of specialist machinery we have many years' experience particularly in building key cutting machines for all current types of automotive keys. For the various application sectors we can offer high-speed key cutters for serial production which are operated manually or fully-automated as well as cutters for after-sales service. Our machines meet all requirements regarding tolerance limits, surfaces and machine capability.

              We would be pleased to supply detailed information on equipment, function and performance upon request.