Smart safety keeps automotive production in high gear

(See PLUS Automation at FoodManufacturing.Live, 15 October 2025, on stand 48)

When a major automotive components manufacturer sought to upgrade its thermostat housing production, it specified a new automated line to increase production efficiency and maintain top-quality standards. The real challenge, however, was to integrate a safety system smart enough to allow for localised stops and interventions without shutting down the entire production line.

The system integrator designed a production line with safety built into the machinery's core concept. With deep experience in the demanding automotive sector, the team knew that simply adding safety measures at the end of the design process wouldn't cut it. The solution needed to be as modular and intelligent as the line itself.

The new production line, commissioned in 2022, is a hive of activity, transforming raw components into fully tested and packaged thermostat housings in an average cycle time of just 35 seconds. The line is divided into five distinct functional zones, each capable of operating independently.

The process begins in Zone 1, where an operator loads components into a roto-friction welder. Once a gasket is added, the part is placed on a pallet and begins its journey. This initial loading area is protected by ReeR Safety light curtains and interlocked guards, allowing for safe operator access when needed.

From there, the part moves into Zone 2 for a series of automated assembly tasks. Springs, bulbs, sensors, and other components, fed by vibratory bowl feeders, are precisely fitted. Crucially, if a component jams here, only this section of the line is paused, ensuring the rest of the production cycle continues uninterrupted.

Zone 3 is all about quality control. The housing undergoes pneumatic and electrical tests, continuity checks, and leakage tests. Parts that pass are labelled using laser-etching for full traceability.

Next, in Zone 4, an automated sorting system separates the good parts from the rejects. The system is sophisticated enough to categorise the reason for rejection, whether it's an electrical fault or an incorrect assembly, providing valuable data for process improvement.

Finally, in Zone 5, an operator performs a final visual check, reads the Data Matrix code to verify all components are present, and applies protective caps before the products are packed for shipment.

A key design feature is that each of the five zones is served by its own air handling unit, allowing for pneumatic power to be isolated to a specific area. This zonal approach was fundamental to the client's requirement for operational continuity.