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Factory Assembly Systems
Catalogue 2006 / 2007
Technologies . Systems . Solutions
Issue date 01.09.2006
We reserve the right of technicalchanges in the course of continous
developement of our products
Layout & Realization:© awiwa communications
www.awiwa.de
11
Factory Assembly Systems
Catalogue 2006 / 2007
Technologies . Systems . Solutions
2
As an international partner of
the automotive industry Dürr
stands for leading edge techno-
logy, high quality and customer
proximity.
With the business unit Factory
Assembly Systems (FAS) Dürr
takes also a leading position
within vehicle’s final assembly
and delivers high-end conveyor
technology, products and systems
for assembly processes in the
automotive industry.
Our portfolio of products and
services is based on extensive
process competence which
translates into our products and
which in turn allow FAS to cover
more than 70 % of the total
investment for equipment
required in a final assembly plant
from in-house manufacture.
Included are products such as
marriage systems, axle assembly,
filling systems, all kinds of con-
veyors, complete end-of-line
equipment, glazing systems and
handling equipment.
Our customers’ requirements
are the main focus of our activi-
ties when working out optimal
process solutions and choosing
suitable products in cooperation.
To do this, we draw upon a
comprehensive base of know-
ledge and experience resulting
from customer relations with
nearly all automobile manufac-
turers worldwide, ranging from
mass production to up-market
production or from compact car
makers to light truck makers.
From planning through to deli-
very and service, FAS accom-
panies the entire life cycle of a
project. Our portfolio ranges
from minute items of equip-
ment to turn-key delivery of
entire assembly shops.
With production sites on three
continents and a most profes-
sional project management we
consistently produce high quality
products and ensure schedule
and budget adherence.
Our strength of innovation
results from our high process
competence. Thus, we are set-
ting on intensive development
activities in all fields.
Our main aim is to perpetually
open new possibilities for our
customers, to reduce their costs
per unit and to increase their
competitiveness.
FAStplant® – the modular way
of erecting, dismantling and
modifying a complete assembly
line is only one example for
innovation made by Factory
Assembly Systems.
Technologies, systems and
solutions – Dürr FAS is optimally
positioned to meet the demands
that the assembly of future-
oriented and cost-conscious
automotive plants brings.
Factory Assembly Systems FAS
3
Contents
Factory Assembly Systems FAS 2
Conveyor Systems : : : : : : : : : : 4
Survey/ System Elements : : : : : : : : : : : : 6 - 9
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 andServer 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
DÜRR Worldwide : : : : : : : : : : 168
4
5
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
Conveyor Systems
6
„Just in time“ or „just in se-
quence“ – Dürr conveyor systems
from the Factory Assembly
Systems business unit meet all
requirements for more flexibility
and cost effectiveness. We set
standards in respect of functio-
nality and innovations with our
extensive range of floor conveyors
and overhead conveyors. We
offer maximum reliability with
reduced maintenance effort.
Two examples are our patented
innovation Twin Trolley System®
(TTS) with its modular structure
and FASmatic®, the automatic
guided vehicle. FASmotion, our
system for non-contact energy
and data supply, can be in-stalled
with almost all conveyor techno-
logies. Thus, Dürr FAS continues
with setting new standards for
higher availability and less main-
tenance.
Dürr conveyor systems:
Innovative – efficient –
and user-oriented
In view of increasing demands
for the reliability of a plant verti-
cal adjustment conveyors with
modern belt technique and
water resisting modular chain
conveyors form an important
part of our portfolio.
Against the background of high-
quality demands we conse-
quently improve our range of
products.
The market success of Dürr FAS
is the result of a continuous
development of our conveyor
systems and the fulfilment of
specific customer demands.
7
The Conveyor Systems
Overhead conveyorsFAStrolley
Power&Free
Electric Monorail System
Twin Trolley System® (TTS)
Vertical Adjustment Conveyor
Floor conveyorsFASfloor
Skid conveyor
TTS inverted
FASmatic®
Skillet conveyor
Belt conveyor / Modular chain conveyor
Slat conveyor
Your Advantage
High reliability
Low maintenance effort
Future-proof thanks to standardized product range
Non-contact energy and data transfer optional
Conveyor Systems Survey
8
Twin Trolley System® (TTS)
Slat Conveyors
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.
Vertical Adjusting Conveyor
Vertical Adjusting Conveyors by Dürr stand for precise adjustingof height and maximum functionality. Its innovative belt techni-que allows minimized maintenance effort.
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.
The convincing features of this conveyor are its rugged chain drive and its high resistance to moisture, dirt and high temperatures.
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.
9
Conveyor SystemsSystem Elements
Skillet
Skillets, optionally with integrated lifting device, allow an optimumworking level for each section. In touch with state-of-the-art partlogistics, it sets up the backbone of innovative "just in sequence"production.
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.
FASmatic®
FASmatic® is controlled by a high-capacity supervisory systemand operates with inductive energy and data transfer. On-boardbatteries and pits are no more necessary and changes in the lay-out can be executed with minimized effort.
Belt Conveyor / Modular Chain Conveyor
As man movers and for vehicle body conveying, belt conveyorsare popular in final assembly. The modular chain conveyor is afurther development of the belt conveyor. It is insensitive againstdirt and requires low maintenance effort.
TTS inverted
TTS inverted is the floor guided version of the Dürr innovationTwin Trolley System® (TTS). The form-fitting drive system joins very high acceleration and exact positioning with minimized spare parts.
10
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Technical Data and Dimensions
Overall size 4” Overall size 6”
Chain pitch 4” 6”
Ultimate load approx. 220 000 N approx. 440 000 N
Conveying speed (standard) 0.5 - 18m/min 0.5 - 18m/min
Horizontal curves 15 - 180° 15 - 180°
Vertical curves 10 - 35° 10 - 35°
Max. payload capacity, double trolley approx. 2,000kg approx. 2,400kg
Higher payload capacities with multiple trolley possible
11
Power & Free systems can be
used both as overhead con-
veyor systems and as floor con-
veyor systems (inverted P&F).
In the automotive industry,
P&F conveyors are used for
in-plant transport in all sectors
from the body shop through the
paint shop to final assembly.
Standardized components of
various sizes are available for
various loads.
Owing to the simple, modular
design, it is possible to imple-
ment different functions, such
as buffering, distribution, bran-
ching or stopping very easily
and at low cost.
P&F systems are very rugged
and can be used easily even
under aggravated ambient
conditions, such as high tem-
peratures or aggressive media
or in welding lines.
System Elements
Rail system, including suspension, consisting of Power& Free rail in size 4”and 6”
Chain, including pusher dogs
Horizontal curves
Vertical curves
Transfers
Trolleys
Drive station
Tensioning station
Switches
Stoppers
Lifting stations
Control system
Overhead Conveyors FAStrolleyPower & Free
Mode of Operation
A Power & Free system
consists of two rails arran-
ged 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.
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Technical Data and System Elements
EMS Light EMS Medium EMS Heavy-dutyVDI 500
Aluminum profile (rail) 180 x 60mm 180 x 60 mm 240 x 80mm
Payload capacity (hanger + load) 500kg /trolley 750kg /trolley 1,800kg /trolley
Transportspeed up to 120m/min 80 m/min 40 m/min
Curves 15°/30°/45°/90° 15°/30°/45°/90° 15°/30°/45°/90°in the case of radius 1,000 and 1,500 mm
Switches 45° in the case of radius 750 mm 45° in the case of Optional rotary switches radius 1,000 mm
Track lengh unlimited unlimited unlimited
13
The electric monorail system
(EMS) is a modular-design over-
head conveyor system for trans-
porting complete vehicles or ve-
hicle bodies and also all pos-
sible attachments, such as doors,
cockpits or seats. The principal
dimensions are standardized in-
ternationally. This system offers
all capabilities of line routing
through an installation. It is also
possible to easily implement
buffer functions, distribution
functions and branch functions.
We are able to supply two ver-
sions of electric monorail system.
EMS Light with 500 kg payload capacityper trolley:This version is used primarily for
transporting attachments such
as doors and cockpit and for po-
wertrain components such as
axles and engines. The dimen-
sions of the aluminum profile are
based on the VDI 3643 Regu-
lation.
EMS Mediumup to 750kg payloadcapacity per trolley:This version is used to trans-
port bodies in white and heavy
components. The principal di-
mensions of the aluminum pro-
file are 180 x 60 mm.
EMS Heavy-duty up to 1,800kg payloadcapacity per trolley:This version is used to trans-
port vehicle bodies in the area
of vehicle final assembly.
The principal dimensions of
the aluminum profile are 240 x
80mm.
Overhead ConveyorsFAStrolleyElectric Monorail System
System Elements
Rail, including energy supply (busbar or FASmotion)
Single trolley
Double trolley
On-board control
Horizontal curves
Vertical curves
Lifting stations
Switches
Hanger (with /without lift)
Field of Application
Vehicle body transport
Transport of miscellaneous hardware and attachments, such as doors, cockpits and engines etc.
14
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TTS - Heavy
Field of Application
Transport of vehicle bodies,
e.g. in final assembly
TTS - Skillet
Field of Application
Combination of TTS with
skillet system. Used, for
instance, on work lines
Transportation is performed
using TTS Heavy outside of
the work lines
TTS - Light
Field of Application
Transport of components,
such as cockpits, doors and
powertrain components
in final assembly
Technical Data and Dimensions
Type
Payload capacity (hanger + load)
Conveying speed on straight sections
Conveying speed in curves
TTS - Heavy
2,500kg/2 trolleys5,000kg/4 trolleys
max. 40m/min
max. 24m/min
TTS - Skillet
2,500kg/2 trolleys5,000kg/4 trolleys
3 - 7.5m/min
–
TTS - Light
600kg/2 trolleys
up to 150m/min
max. 30m/min
15
TTS - Light
4/5/6/7/8 meters
15°/30°/45°/90°at radius of 600mm
max. 30°
30°/45°/90°at radius of 600mm
Aluminumextruded profile
unlimited
TTS - Heavy
4/5/6/7/8 meters
15°/30°/45°/90° atradius of 1,500 mm
max. 20°
30°/45°/90° at radius of 1,500mm
Aluminum extruded profile
unlimited
TTS - Skillet
4/5/6/7/8 meters
––
––
––
Aluminumextruded profile
with 1 push drive36-84 m, longerlengths on request
Preferred values in bold
The innovative Twin Trolley
System® (TTS) with its modular
drive concept overcomes
upgrade sections without the
need for additional installations.
We can thus implement high
speeds with no slip and no
appreciable wear. Provided
with flexible hanger, the vehicle
bodies can be lowered to any
working height. It is also pos-
sible to operate with an over-
head skillet line in the further
development, the Skillet TTS.
Options
Lifters
Hanger (with / without lift)
Overhead ConveyorsFAStrolleyTwin Trolley System®
System Elements
Type
Straight rail section
Curves
Upgrade/downgrade section
Switches
Rail profile material (straightsection / curve / switch)
Track lengths
Straight section
Horizontal curve
Vertical curve
Switch
Basic elements
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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
17
Overhead ConveyorsFAStrolleyVertical Adjusting Conveyor
Field of Application
Overhead conveyor with vertical adjustment in BIWpaint and final assembly
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)
With monorail and twin trolley
systems, vertically adjustable
conveyor hangers can be used
from the body shop right through
to the final assembly shop. Their
standardized modular design
allows adjusting the height to
the desired position and also
meets high ergonomic require-
ments. The goods to be trans-
ported are loaded and unloaded
by adjacent conveyors.
Both continuous and intermit-
tent ope-rations are possible.
The application of belt techni-
que reduces the maintenance
requirements substantially.
18
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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
19
Floor Conveyors FASfloorSkid Conveyor
Skid conveyors are modular con-
veyors customized to meet indi-
vidual needs in body, paint and
final assembly shops. Standar-
dized mechanical and electrical
systems using identical compo-
nents permit keeping a reduced
number of spare parts in stock
at maximum reliability (≥ 99.5 %).
Continuous and intermittent
operations are possible.
Field of Application
Skid conveyors for bodyshop, paint and final assembly
Application in high tempera-ture area
Application in wet area
Application in ex-area
Dürr offers pre-mounted, pre-
installed and tested mechatronic
systems fitted with belts in the
normal temperature range (no
lubrication, thus low mainten-
ance requirements), and fitted
with chains in the high tempera-
ture range (up to 220° C). Thanks
to modular design, all material
flow functions such as buffers
and distribution systems can be
built in a flexible manner.
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
UBS-Shuttle
20
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Technical Data
Payload (tooling plate + work piece)
Conveying velocity on straight sections
Conveying velocity in curves
Horizontal curve
Vertical curve
700 kg
till 100 m/min
max. 30 m/min
Radius = 1,000 mm
Radius = 2,000 mm
21
Floor Conveyors FASfloorTwin Trolley System®
TTS Inverted
The compact design of the Inver-
ted TTS conveyor system offers
good body accessibility and the
incorporation of a toothed belt
drive ensures exact positioning.
The high acceleration that is pos-
sible with an Inverted TTS makes
it an ideal system for shuttle
applications. Using identical tech-
nology for both overhead and
floor conveyors reduces the num-
ber of different conveyor systems
required and this in turn reduces
the range and number of spare
parts that have to be kept in
stock. In addition, the skillet ver-
sion of this system has the advan-
tage of needing fewer drive units.
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
Basic elements
Horizontal curve
Straight section
Switch
Vertical curve
22
Technical Data
Chassis- and 4-wheel-concept 4-wheel-conceptsteering concept Single wheel-steering Center pivote plate-
front + back steering front + back
Payload (incl. till 3,500 kgtooling plate)
Running velocity till 60 m / min
Energy transfer FASmotion (non-contact)
Line guidance inductive (non-contact)
Vehicle communication via funk (WLAN)
Superstructure scissors lifting table, lifting device, tooling fixture
Track length unlimited
References VW Mosel (Golf A5) BMW Leipzig, S-GM ShanghaiVW Mosel (Passat B6) MBUSI Tuscaloosa, KIA ZilinaF
AS
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FASmatic® is a new floor con-
veyor system which is mainly
used in discrete manufacturing
for dress-up stations and the
marriage process in general
assembly. It is applicable in con-
tinuous flow as well as in stop
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
Field of Application
Floor conveying in discrete manufacturing
– Dress-up area– Unit assembly / fitting– Sub-assembly conveying
designed freely, pits are no more
necessary. In energy supply, non-
contact energy transfer FAS-
motion does replace batteries.
This ensures trouble-free conti-
nuous operation with high availa-
bility and low maintenance effort.
System Elements
Floor installation
Stationary control
Vehicle underframewith steering concept
Lifting unit
Tooling fixture (swimming function optional)
Energy transfer FASmotion
Line guidance
Data transfer
Safety equipment
Onboard control
Floor Conveyors FASfloorFASmatic®
24
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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 mmWidth approx. 3,000 mmOther dimensions on request
25
This system is used in the sec-
tors of vehicle final assembly
and body shop.
The skillets are suitable for foot
traffic and may be equipped
with various superstructures
for accommodating the vehicle
bodies. If eccentric lifting tables
are used, the working height
of the vehicle body can be ad-
justed variably so as to ensure
an optimum working position.
The skillet can be powered via
conventional busbars or also
using non-contact energy and
data transfer FASmotion.
Besides the actual skillets, a
skillet line contains the following
chief components: docking
drive, main drive, braking drive,
undocking drive and roller strips
on which the skillets lie.
The skillets may also be moved
on roller beds, lifters and cross
conveyors outside of the actual
skillet lines.
System Elements
Skillets with/without lifting table
Lifting tables hydraulic/with spindle/with belt
Track
Power supply busbar/ non-contact energyand data transferFASmotion
Main drive based on friction wheel
Docking and undocking drives
Roller beds
Cross conveyors
Lifters
Floor Conveyors FASfloorSkillet Conveyor
26
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Technical Data
Skid Man mover Vehicle Vehicle conveyingcross conveying conveying special applications
Case of Cross conveying Conveying Conveying of Conveying ofoperation for Skid in bodyshell of men vehicles on vehicles on wheels
work, paint and wheels through leak testfinal assembly
Distance Standard till 15m Standard till 100m Standard till 100m Standard till 100mbetween axles
Payload 700/1,400/2,000 kg 400 kg 3,000 kg 3,000 kgskid + workpiece on 6m length on 6m length on 6m length
Transport- 4 till 20m/min 0.5 till 10m/min 0.5 till 10m/min 0.5 till 10m/minvelocity
Width 1,400kg 2x100mm maximal 4m maximal 4m maximal 4m2,000kg 2x200mm
27
Floor Conveyors FASfloorBelt Conveyor /Modular Chain Conveyor
A distinction is made in the
case of belt conveyors and mo-
dular chain conveyors in the
sector of vehicle transport bet-
ween man movers and con-
veyor belts for vehicle body
transport.
Man movers:
These are normally 1 to 4m-
wide belts on which the wor-
kers “ride” at the same process
speed as the main line. The
vehicle body is transported
in an overhead conveyor for
instance while the worker rides
on a man mover below the
vehicle body at the same speed
as the vehicle body itself.
Overhead operations can be
configured ergonomically with
this arrangement.
Vehicle body transport:
The vehicle bodies are normally
transported with their wheels
on the belt or the modular chain.
Basically, there are two types:
Type 1:
Wide belt with a width of
approx. 1 to 4m for transporting
vehicle body and, if applicable,
worker.
Type 2:
Twin-strand belt with a width
of approx. 300 – 500mm.
Modular chain conveyors are a
low cost alternate to slat and
belt conveyors as it is possible
to replace single modules, and
their low structure calls for far
smaller pit dimensions. In con-
trast to belt conveyors, these
conveyors are driven by form-fit
connection and not by friction.
Since it is not necessary to
weld belts on site, maintenance
requirements, wear and tear
are notably lower than with
conventional belt conveyors.
System Elements
Base frame with track
Modular chain conveyor
Drive unit
Deflection unit, if applicablewith braking drive
Field of Application
Skid conveying
Man mover
Vehicle body conveying
Vehicle body conveyingthrough leak test
Base framewith track
Deflec-tion unit
Drive unit
Drive
28
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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 mmSingle-strand version approx. 3,000 mm
29
On slat conveyors, vehicle bo-
dies are transported through
the body shop or vehicles are
transported through final as-
sembly. Owing to the rugged
chain drive and the high resi-
stance to moisture and dirt, this
system is ideally suited to wel-
ding areas in the body shop, the
car final area and leak test in
vehicle final assembly.
System Elements
Chain with slats
Base frame
Drive unit
Deflection and tensioning unit
Floor Conveyors FASfloorSlat Conveyor
Field of Application
Transporting vehicle bodies
Transporting vehicle bodies in the wet area (leak test)
