For the assembly of gearbox components, the Sohland gearbox plant required a solution that combined ergonomics, functionality and efficient workflows. In collaboration with Dr Matzat, a modern assembly workstation was developed featuring electric height adjustment, integrated storage options and optimal integration into the existing material flow.

With the introduction of new gearbox types, the demands on pre-assembly at the Sohland gearbox plant increased. The existing workstations offered neither ergonomic height adjustment nor sufficient storage space for tools, pressing fixtures and components.

This led to poor working postures, additional transport distances and unnecessary handling steps, particularly when dealing with longer and heavier assemblies weighing over 15 kg. At the same time, parts frequently had to be transported between the central pre-assembly area and the individual assembly lines.

A workstation concept was therefore sought that

• allows an ergonomic working height for different employees,
• combines pressing and assembly tasks at a single workstation,
• keeps tools and components within easy reach,
• reduces transport distances and
• improves the flow of materials within the assembly process.

In collaboration with Dr. Matzat, ROEMHELD developed an ergonomic workstation system with electrically height-adjustable lifting columns as its central component.

The central components of the solution are two electrically height-adjustable Shop-Floor lifting modules, which allow the working height to be individually adapted to the respective employee as well as to different assemblies. This enables both pressing operations and subsequent assembly steps to be carried out whilst maintaining an ergonomic posture.

A synchronisation control system ensures precise and lifting of the two lifting modules. The height adjustment is conveniently operated via pushbutton.

The workstation is complemented by integrated storage compartments for tools, pressing fixtures and assembly components. All necessary work equipment is located directly at the workstation and is accessible at all times.

The workstations have been integrated decentrally across a total of five pre-assembly stations. In some cases, the assemblies are transferred directly to final assembly via roller conveyors. This eliminates unnecessary transport and the need for additional storage areas.

The robust design of the ROEMHELD components, together with the close collaboration between Sohland gearbox plant, Dr. Matzat and ROEMHELD, ensured a solution optimally tailored to the assembly process.

Technical data

• Press-in force 63 kN

• Press stroke 500 mm

• Operating pressure 20–200 bar

• Table stroke 400 mm

• Lifting force 6,000 N

Thanks to the height-adjustable workstations, pressing and assembly work can be done in an ergonomic working posture. The flexible height adjustment allows for the optimal positioning of workpieces weighing over 15 kg, thereby supporting a variety of assembly tasks. At the same time, material flow and workstation organisation have been significantly improved.

The key benefits:

• ergonomic adjustment of the working height to suit staff and assemblies
• significantly reduced physical strain
• shorter cycle and throughput times
• Pressing and further assembly steps at a single workstation
• less material handling within the assembly process
• Reduced changeover effort
• Higher assembly capacity
• Better utilisation of existing assembly space

The expectations were fully met. Time savings, ergonomics and efficiency were improved as planned. The roll-out of the new workstations was extremely successful: feedback from the assembly line on the new solution was consistently positive.