Aebi Schmidt, a manufacturer of vehicles for cleaning, clearing, and maintaining traffic and green spaces, has achieved a remarkable feat: increasing throughput, productivity, and flexibility in the production of complex, multi-variant components while simultaneously improving ergonomic workstations—all within a smaller footprint. The company credits this success to the Centrick rotating and tilting manipulator, which they use for assembling large cabs and hoppers.

The assembly of dirt strainers and cabs is a crucial step in producing sweepers like the Swingo 200+, manufactured by Aebi Schmidt in St. Blasien near Freiburg.

“It is important that the assembly process is flexible and simple and that both the productivity of the department and the ergonomics of the workstations are optimally designed,” says Philipp Jacoby, the 28-year-old coordinator for production planning and staff deployment responsible for the Swingo compact sweepers with 2 m³ hoppers.

Since implementing the Centrick rotating and tilting manipulator for the Swingo 200+, there is no longer a need for extensive employee training on the production line. Previously, workers had to acquire the necessary expertise to handle the complex assembly processes of the product.

Production times for the roughly 450 Swingo series compact sweepers with 2 m³ hoppers produced each year vary significantly, complicating personnel planning. While a standard model might be completed in eighty hours, a version with extensive additional equipment can take nearly twice as long.

“The large number of possible variants resulted in very different capacity utilization during assembly. Together with the workflows being synchronized, the staff’s scheduling became a challenge and slowed production down,” explains Jacoby.

Variants and Seasonally Fluctuating Orders

Another characteristic feature of the production of the series is the strong fluctuation in incoming orders over the year from customers throughout Europe,” says Philipp Jacoby.

The work wasn't always comfortable for the 35 employees. For instance, installing dirt strainers on the sweepers required climbing into the interior of the voluminous hopper lying on the floor and mounting the components while partly lying on their backs. This task demanded a high level of routine, skill, experience, and mobility.

Similar skills were needed to install the vehicle's steering system, including its hydraulic supply, brake booster, and pedals, on the bottom of the sweeper cab. To do this, employees had to first crawl under the cab, which weighed around 440 kg, and secure it to a frame. After getting back up, they would use a lifting device to move both into a vertical position before they could begin assembly.

Introducing the Centrick Rotating and Tilting Manipulator

In collaboration with Gebhard Lehner, a work planner at Aebi Schmidt, Jacoby devised a solution to enhance the situation. “We are always looking for ideas to simplify our work and activities,” says Lehner. expressing his drive as a work planner. He found a pivotal source of inspiration at a trade fair, “At the Motek I saw at a stand how an engine block and a lawn mower were moved with the Centrick rotating and tilting manipulator. I knew right away:  that's what we need.”

The ROEMHELD Centrick is an electrically powered rotating and tilting manipulator designed for the mobile assembly of heavy components weighing up to 4,405 kg. Workpieces can be tilted by 90°, endlessly rotated, and optionally lifted. All axes are driven electrically and are free of backlash. Brakes securely hold the position in place. A unique arrangement of articulated arms and patented tilting kinematics ensure that the workpiece's center of gravity remains stable, maintaining the optimal assembly position at all times.

Compact Design for Limited Spaces

The Centrick boasts a significant advantage over traditional rotating and tilting fixtures, particularly in confined spaces. Unlike most fixtures, which typically have only one arm and swivel over a much larger range, the Centrick's compact design ensures minimal variation in working height, promoting ergonomic working conditions.

With a small swivel radius, the Centrick ensures exceptional stability, while its reduced spatial requirements compared to conventional tilting processes allow for seamless integration into existing work areas, even in tight spaces.

Comfortable and Ergonomic Assembly in a Standing Position

With the use of the Centrick, assembly of the hopper, which weighs over 220 kg and measures 90 x 210 x 130 cm (H x L x W), is now nearly fatigue-free. The hopper is transported to the assembly workstation on a rack, where the employee attaches it to the rotating and tilting manipulator. Using the pick-up device, the employee positions the component for attachment to the sweeper. With the cable-bound two-hand operation, the employee can rotate the workpiece by 90 degrees at the push of a button. This allows for comfortable and ergonomic assembly of dirt strainers on the sides and in the middle of the hopper while standing.

Similarly, working on the cab has also become easier. The operator places it into the Centrick along with its transport rack. With the push of a button, the manipulator securely moves the 440 kg part to the desired position. The fitter can then easily attach all components to the bottom while standing. Subsequently, the cab is transported on its rack to the next station for further work steps.

Streamlined Integration of Additional Employees in Production

After significant ergonomic improvements to the assembly workstations, the Swingo line team embarked on converting production into a dynamic, adaptable system the following year. This transformation, termed "breathing production," enables the assembly department to swiftly respond to changing order volumes: weekly production can be more than doubled in real-time with minimal adjustments and, if necessary, scaled back down.

A crucial aspect of this new work organization was the ability to quickly onboard additional employees, including temporary workers hired on short notice, into production. The two Centrick manipulators play a key role in ensuring that assembly work on the cab and hopper maintains high productivity even with less experienced personnel, shortly after their introduction.

During the restructuring process, the two manipulators were easily relocated and seamlessly integrated into the new workflows. For users seeking to utilize these compact high-tech tools for mobile applications, lockable rollers are available as an optional feature for easy movement.

The Centrick is currently offered in two basic versions: one for loads up to 500 kg and another for loads up to 2,000 kg. The smaller A500 variant operates on a scissor principle with a 310 mm stroke, while the A2000, featuring a column construction, lifts heavier loads by up to 1,000 mm. Both versions come standard with tilting and rotating axes, with the lifting function available as an option. Additional optional features include a media feed-through for the rotary axis, operating elements for welding applications, and safety devices. These manipulators are driven by low-noise 230 V AC electric motors, with power consumption typically below 700 W due to their efficient kinematics.

ROEMHELD Centrick: A Game-Changer for Aebi Schmidt

Aebi Schmidt uses a Centrick A500 for tilting with scissor lift for their assembly of cabs, and a version for tilting and rotating without lifting for hoppers. “The standard cabler emote control is sufficient for our requirements. Thus, we can do without an enclosure and save space,” explains Lehner.

In addition to the push-button operation, another option offers controlled height, rotation, and tilt adjustments through a programmable teach-in control, ensuring repeatable, process-controlled series production. Additionally, a radio remote control option is available for towing with driverless transport systems and for use on conveyor systems.

Production planner Philipp Jacoby praises the two manipulators for saving significant time while simultaneously enhancing handling safety and ergonomics at Aebi Schmidt.

Jacoby continues, “The ROEMHELD service is fast when something needs to be done, and the spare parts supply is excellent.”

About Aebi Schmidt

Aebi Schmidt Group stands as a premier global provider of intelligent product systems and services catering to the cleaning and clearing of critical traffic areas and the maintenance of green spaces in challenging terrains. Our diverse range encompasses vehicles, innovative attachments, and superstructures for custom vehicle enhancements, along with a comprehensive suite of services for tailored customer solutions. In March 2019, the brand structure was streamlined, consisting of the brands Aebi, Schmidt, Nido, Meyer, Swenson, and MB. Aebi Schmidt Holding AG is headquartered in Frauenfeld, Switzerland, with another location in Zurich.

About ROEMHELD

For over six decades, the ROEMHELD Group has played a vital role in manufacturing industrial commodities and consumer goods across various sectors, including aircraft, automobiles, machine tools, and smartphone cases.

Our core focus is on providing efficient clamping technology solutions for workpieces, as well as dies in forming technology and plastics processing. These solutions form the cornerstone of our ever-expanding portfolio. Additionally, we offer a comprehensive range of components and systems for assembly and handling technology, drive technology, and locking mechanisms for wind energy system rotors.

With a diverse catalogue boasting approximately 20,000 items, we are dedicated to developing and delivering customized solutions tailored to meet specific needs. Our commitment to quality has earned us international recognition as one of the foremost leaders in the industry today.