WE UNDERSTAND AUTOMATION – BRAUN SONDERMASCHINEN GMBH

Automation, Industry 4.0 and Big Data are the biggest technology trends of our time. We at Braun recognised these trends early on and have used them consistently to develop highly automated special machines. With customised special machines we help you increase the productivity of your production lines and realise savings potential. We conceptualise, design and construct special machines, production plants, production lines and coating systems according to your individual ideas.

We have been there for you for over 35 years with our special machine construction services: Braun conceptualises, designs and constructs individual production plants and coating systems according to customers’ wishes. To do this, we draw on industry-wide technology trends such as electromobility, automation and Industry 4.0.

Are you looking for an experienced special machine construction company to optimise your production plants? Then you have come to the right place. With Braun Sondermaschinen GmbH you have an experienced automation partner at your side.

SPECIAL MACHINE CONSTRUCTION MACHINE CONSTRUCTION FINAL ASSEMBLY LINES PRODUCTION LINES ASSEMBLY LINES SPECIAL MACHINES MANUAL WORKSTATIONS MACHINE CONSTRUCTION CONTRACT MANUFACTURING ELECTRIC MOTOR PRODUCTION TEST STATIONS PRODUCTION PLANTS EPOXY COATING SYSTEMS PAINT LINES NOK CONCEPTS HAIRPIN STATOR COATING PALLETISER AUTOMATED GUIDED VEHICLE SYSTEM AGV

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Sondermaschinenbau Sondermaschinen Fertigungslinien

INDIVIDUAL SPECIAL MACHINE CONSTRUCTION USING THE MODULAR AUTOMATION CONCEPT (MAC)

With our special machines and production lines, your production facility is prepared for future tasks – during planning and realisation, we place the highest priority on scalability, modularity and implementation of your product variety in the production lines. Our production plants and special machines are also equipped with the latest technologies and impress with their long life and efficiency. Naturally, we offer a functioning and complete solution with hardware, software and a comprehensive service package.

Sondermaschinen Assambly line Produktionsline Montageline Taktzeitreduziert Taktzeitreduzierung

THE BRAUN MAC RAPID CYCLER WITH CYCLE TIME OF < 1 SECOND

You think cycle times of less than a second are ambitious? With the Braun rapid cycler, you can manufacture even complex production goods quickly, effectively and with excellent quality.

The unique selling point of our modified MAC module is consistent focus on customer-specific needs. Like all of the MAC modules, the Braun rapid cycler also offers a complete solution with hardware and software. Through this you can even produce special electronic goods with a cycle time of less than a second.

Sondermaschinen Palettierer Palettierer mit FTS Anbindung Palettierer für Fahrerloses Transportsystem

EFFICIENT LOGISTICS WITH THE BRAUN PALLETISER FAMILY

In addition to our fully and partially automated production lines, we offer you automatic coverage of factory logistics with our palletiser family. Focus here is on efficient supply of the production lines as well as removal of semi-finished products and finished components. With the Braun Sondermaschinen palletiser family, you have the right palletiser for any requirement.

Sondermaschinen Flurförderfahrzeug Fahrerloses Transport System

THE AUTOMATED GUIDED VEHICLE SYSTEM (AGVS)

The productivity of production lines depends to a large extent on the efficiency of the internal transport logistics. With our automated guided vehicle system (AGVS), you profit from significant efficiency gains and cost reductions through the unmanned and direct delivery of materials to production lines. Our special machines make completely autonomous loading and unloading possible for you.

Sondermaschinenbau Sondermaschinen Fertigungslinien Fertigungslinienhersteller Maschinenbauer Sondermaschinenbauer Beschichtungsanlagen Hairpin Statorbeschichtung

SIMPLE AND EFFECTIVE: POKA-YOKE MANUAL WORKSTATIONS & TEST STATIONS

Setting up of manual workstations is recommended if the volume is manageable or the activity could only be automated with a large investment. The advantage: Manual workstations can selectively be integrated into automated production lines or built as ‘standalone’ solutions. In both cases we ensure efficient, needs-based and ergonomic design of the workstations according to the latest ergonomics findings.

Sondermaschinenbau Sondermaschinen Fertigungslinien Fertigungslinienhersteller Maschinenbauer Sondermaschinenbauer Beschichtungsanlagen Hairpin Statorbeschichtung

INDIVIDUAL SOLUTIONS FOR ELECTRIC MOTOR MANUFACTURING

With state-of-the-art production plants, electric rotor assembly and electric motor insulation can be designed to be ecological, cost-efficient and highly productive. Braun Sondermaschinen GmbH is at home both in the manufacture of electric motors and in the construction of assembly and coating systems and manufactures the production facilities for nearly all well-known electric motor manufacturers. In particular, we have continuously improved the insulation coating process and set new standards. We developed the revolutionary hairpin stator coating system in 2013 on the basis of the experiences gained.

Sondermaschinen Sondermaschinen Fertigungslinien Fertigungslinienhersteller Maschinenbauer Sondermaschinenbauer Beschichtungsanlagen Hairpin Statorbeschichtung

INSULATION SYSTEMS FOR E-MOBILITY / HAIRPIN STATOR COATING

Stator powder coating using hairpin coating systems is a central step in modern electric motor manufacturing. The hairpin coating system reliably welds the hairpins with epoxy and creates the basis for a long component service life. Thanks to our lengthy experience in epoxy coating systems, we have succeeded in developing a technically mature process.

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OTHER SERVICES

Apart from providing comprehensive service and warranty offerings for our special machines, we offer additional services in connection with special machine construction.

Our variant-rich contract manufacturing facilities can produce the desired one-offs, components, lot sizes or even pre-assembled components for you – even at low volumes. Fast and flexible when it comes to the material – outstanding when it comes to quality.

Excerpt of our reference customers in special machine construction

SPECIAL MACHINES CONSTRUCTED TO PERFECTION

WE AUTOMATE YOUR PRODUCTION AND ASSEMBLY LINES – YOUR ADVANTAGES:

  • fully automated goods inflow and outflow via AGVS with material distributor
  • needs-based palletising – from tray, small load carrier and pallet unloading all the way to ‘bin picking’
  • feeding of a wide variety of production materials with a high level of automation
  • development of highly automated assembly lines for your product: Joining, screwdriving, laser welding, feeding, palletising, adhesive bonding, dispensing, resistance welding, storage, application and much more
  • accommodation of variants with on-the-fly changeover via distributor
  • efficient marking of products: Bar codes, QR codes, labelling, laser inscription and much more
  • inspection technology including NOK concept
  • data connection for formula management, SPC analysis, PPM analysis, serial number management, ERP system and much more

Process examples

Do you have specific requirements for the design of your special machine? No problem: We can design your individual production line or assembly line to be ESD-capable or for SaS2 or SaS3 cleanliness level clean rooms.

Automated production lines offer the potential for sustainably lowering production costs for products across all industries. We offer special machines for the following product categories:

  • intricate electronic articles such as control units or vehicle remote keys
  • technically sophisticated automotive and aviation products as well as high-end construction products
  • assembly lines and coating systems for electric motors, stators and rotors
  • electromobility: Hairpin stator coating, I-pin coating, continuous hairpin coating with impregnation
  • consumer goods: black goods and white goods

Profit from the possibilities of highly automated production processes and increase the efficiency of your production lines.

SPECIAL MACHINE CONSTRUCTION AND LOGISTICS CONCEPT FROM A SINGLE SOURCE

BASICALLY, WE MAP THE FOLLOWING PLANT PROCESSES:

  • Fully automatic inflow of goods via AGV (AGV, AGV) with material station
  • Palletizing (from trays to pallet unloading to “grip in the box”)
  • Feeding of your product components with high autonomy
  • Assembly of your product (welding, joining, gluing, screwing, coating, painting see also processes)
  • Assembly of several variants possible via station and MAK module
  • Labeling (common barcodes, QR codes, labeling, laser labeling, etc.)
  • NIO conception
  • Data connection to recipe management, SPC, PPM analysis, serial number management, ERP system, etc.
  • Palletizing (from e.g. tray loading to bag filling)
  • Fully automatic goods discharge via AVGS

We can design your individual production line or assembly line to be ESD-capable or for SaS2 or SaS3 cleanliness level clean rooms.

We offer special machines for the following product categories:

  • filigree electronic products
  • automotive products, aerospace products, high end building material products
  • Assembly solutions and coatings for electric motors/stators/rotors,
  • Electromobility: hairpin coating, I-pin coating, etc.
  • Consumer goods products (brown and white goods)

Please contact us! We develop your individual production and factory concept.

MAC – PROVEN WORLDWIDE IN SPECIAL MACHINE CONSTRUCTION

MAC – SCALABLE, EXPANDABLE, EFFICIENT

More and more manufacturer are using highly efficient, scalable and expandable special machines – these special machines call for new, needs-based hardware and software solutions. Our modular automation concept MAC (MAK) is the answer: The MAC is a standard for fast, flexible, modular and scalable plant design and represents a mature standardisation basis in special machine construction.

MAC has proven itself worldwide in practice and gives manufacturing companies the possibility of seamlessly integrating new product variants into their production lines. In the planning and realisation of your plants, we use our technically mature modules and components – as a result, you receive a tailored system for your individual requirements.

The key features of the MAC at a glance:

  • modular system with standardised components
  • ahortening of throughput times
  • acalable automation
  • high flexibility in the integration of new product variants
  • integrated logistics for inward transfer of components and outward transfer of finished parts
  • fast, worldwide relocation of production lines possible

Through our modular MAC system, we can offer you a variable layout design – adapted to your current and future requirements.

HAIRPIN STATOR COATING SYSTEMS FOR E-MOBILITY

THE INSULATION COATING IS THE KEY

The future of mobility is electric. That’s why we have been working intensively on coating systems for stator and rotor insulation in electric motors for more than 25 years now. In doing so, we look to innovative, future-oriented solutions for insulation of hairpin and I-pin stators. As technology drivers, we work closely with the scientific community and support research institutions such as KIT (Karlsruhe Institute of Technology) in developing solutions for electromobility.

The stator powder coating using hairpin coating systems is one of the keys to the future of e-mobility. The technical heart of the hairpin coating system is the reliable welding of the hairpins with epoxy – this process ensures durable, safe insulation. Thanks to our years of experience in developing ultra-modern epoxy coating systems, we can now offer you an efficient process with a high level of automation.

Overview of advantages:

  • hairpins are reliably covered
  • low risk of bridging between individual pins
  • thorough coating: The powder also reaches hard-to-access regions
  • flexible assembly cells with scalable solutions

Together with our partner we realise modern coating and impregnation solutions for e-mobility. In this way we use ecologically and economically meaningful synergistic effects. Would you like to find out more about our hairpin or epoxy coating systems? We would be happy to send you practical, informative videos.

EFFICIENT ELECTRIC MOTOR PRODUCTION WITH BRAUN COATING SYSTEMS

ELECTRIC MOTOR ASSEMBLY AND ELECTRIC MOTOR COATING

Thorough, reliable insulation is the cornerstone of electric motor manufacturing. The impressively high availability of our epoxy coating systems of more than 95% is achieved both through imaginative handling technology and through advanced transport equipment for production goods passing through the epoxy coating systems. Using defined inspection features, we guarantee consistently high quality in our special machines for coating.

With our coating systems you profit from:

  • optimal edge coverage
  • perfect layer thickness of the applied coating
  • high mechanical impact resistance of the coating
  • quality guarantee thanks to electronic insulation testing

In our epoxy coating systems, we avoid heating the product prior to coating – this allows us to recover the excess powder and feed it back into the ‘fresh powder’ in an ecologically sound manner – without any waste.

Do you need videos of our epoxy coating systems? We would be happy to send you information.

INDIVIDUAL MANUAL WORKSTATIONS AND TEST STATIONS

ERGONOMICS IS THE KEY

Automation and manual work are not mutually exclusive. On the contrary, Modern manual workstations for the manufacture and assembly of products with the highest quality standards will continue to be an integral part of the manufacturing industry in the future. That’s why we offer conceptual design, development and construction of ergonomic manual workstations ideally tailored to the employees – for production lines and for standalone solutions.

We place the highest value on the ergonomic design of the workstation and an efficient production area design. We design the manual or partially automated workstations according to the simple and effective poka-yoke concept to enable the highest and most error-free possible output of production goods or goods to be tested.

In the planning of manual workstations and test stations, we cooperate closely with our customers and incorporate individual wishes and requirements into the design.

EFFICIENT LOGISTICS WITH INDIVIDUAL, SCALABLE AND MODULAR PALLETISERS

THE BRAUN SONDERMASCHINEN PALLETISER FAMILY

With our palletisers from the proven BS family, we offer our customers an individual, scalable and modular logistics concept that enables functionally coordinated material logistics for current and future requirements. The palletisers can automatically supply your assembly lines – economically, efficiently and with low maintenance requirements.

In order for us to be able to offer you the right solution for each individual requirement, there are currently five basic versions to choose from in the BS palletiser family. We would be happy to adapt them to your individual needs.

Depending on the desired level of expansion, we offer our palletisers in a customer-specific configuration – as a standalone variant with its own control or as an integration module with predefined interfaces to the customer facility. You can also choose freely when it comes to the handling: We can completely install the feed-in to the production line – or you can operate the transfer point yourself. We integrate all common handling variants, such as robots, axis portals or gripper systems.

Thanks to the modular and flexible system, we can handle a wide variety of loads with our palletisers: The range extends from blister packs through tray stacks all the way to trays or small load carriers on Euro pallets. We can also provide loading and unloading of load carriers on trolleys with our palletisers. Thanks to the large payload range from 40 kg to 800 kg, our special machines can palletise almost any product on a customer-specific basis.

WELCOME TO INDUSTRY 4.0

EFFICIENT LOGISTICS CONCEPTS AND PRODUCTION LINES WITH THE BS TRAY FEEDER

The precise coordination of logistics and production line has a decisive influence on the efficiency of production processes – this is exactly where the BS tray feeder MiR250 comes in and represents the link between logistics and production.

With our autonomous mobile robot (AMR), we enable the autonomous reproduction of supply and disposal in production plants. The main task of the robot is to pick up the production material from the logistics areas and automatically feed it to the production facility. In addition, the innovative system is also able to transport semi-finished products to the next production stage. The integration of intermediate storage areas or buffers is also possible.

Owing to the variable transfer height of 200 to 1200 mm, the BS tray feeder MiR250 is the ideal addition to our BS palletisers. With this a complete special machine with maximum autonomy arises. The BS tray feeder MiR250 shows its strengths wherever safe manoeuvring in confined spaces is required.

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