Realis Technology

Case Studies

Systems in production

Ordered by scale and technical difficulty — full production lines first, then the specialized stations and cells. Every figure below comes from a system that was built, accepted and put into daily production.

Full production line

Electric compressor assembly & test line

A complete line for automotive electric A/C compressors — auxiliary line, main line, controller assembly and completion line, delivered as one turnkey program.

  • Stator shrink-fitting into the housing with in-line height verification
  • Servo press-fitting throughout, with force and displacement curves recorded per unit
  • Rotor magnetization with magnetic flux verification before assembly continues
  • Helium charging and leak testing, insulation and hi-pot validation, end-of-line start-up test
  • Every process parameter written back against the unit serial number

Watch this line running →

Takt
25 s
Operators
18 per shift
Line segments
4
Scope
Turnkey, incl. layout
Electric compressor assembly and test line in operation
Line layout — Electric compressor assembly & test line

Full production line

Conventional compressor production line

The largest line in the portfolio and the fastest cycle — nine linked equipment groups covering the whole compressor build, from offline sub-assembly through degreasing to line-off.

  • Offline sub-assembly feeding three parallel main lines
  • Dedicated inspection line integrated into the flow, not appended at the end
  • Degreasing line handled inside the same program and takt
  • Completion line with final validation before line-off
  • A 12-second cycle sets the pacing constraint for every station and transfer in the line
Takt
12 s
Operators
33 per shift
Equipment groups
9
Includes
Degreasing + inspection lines
Line layout — Conventional compressor production line

Full production line

HVAC box assembly line

Twenty-three stations taking an automotive HVAC unit from evaporator core pre-assembly all the way to line-off, with four inspection machines built into the line.

  • Evaporator core pre-assembly through to completion and offline in one continuous flow
  • Core leak detection integrated in-line
  • Air-velocity testing to verify airflow performance
  • Missing and incorrect part detection before the unit advances
  • Noise testing as a final quality gate
Takt
90 s
Stations
23
Operators
23 per shift
Test machines
4
Automotive HVAC unit assembly
Line layout — HVAC box assembly line

Full production line · Export program

HVAC box assembly line — Mexico

The same HVAC assembly program delivered to a customer plant in Mexico: five sub-assembly streams feeding a five-stage main assembly process, ending in combined vision, appearance and function inspection.

  • Sub-assembly: case heater, case intake, evaporator, internal heat exchanger and blower motor, each built on its own stream
  • Parts picking for actuator assembly feeds the case heater line directly
  • Main assembly sequences case heater, case intake, heat exchange and blower motor
  • Combined vision, appearance and function inspection as the single release gate
  • Proof that the same line design transfers to a plant outside China
Destination
Mexico
Sub-assembly streams
5
Main assembly stages
5
Final gate
Vision + function
HVAC assembly process flow — sub-assembly and main assembly stages

Full production line

PTC heater production line

An automated line for PTC cabin heaters, built around thirteen machines with a lean operator count.

  • Thirteen linked machines covering assembly and test
  • Six operators per shift across the whole line
  • Automated transfer between stations with in-process verification
Takt
50 s
Machines
13
Operators
6 per shift
Scope
Turnkey line
PTC heater automated production line

Specialized test station

AI-based NVH test equipment

A noise and vibration test station that reads the product the way an experienced inspector does — and does it on a production floor, without an acoustic room.

  • Real-time acquisition of product sound together with vibration in three directions
  • Stethoscope-principle acoustic pickup that is unaffected by surrounding factory noise
  • No soundproof enclosure needed — the station drops onto the line and tests at takt
  • A deep-learning model separates NG from OK parts in real time, with no operator judgement
  • Identifies most categories of missing-part faults, not just overall noise level
Signals
Sound + 3-axis vibration
Acoustic room
Not required
Decision
Real-time NG / OK
Detects
Most missing-part types

Retrofit + traceability

Car tailgate riveting equipment

Operator-guided riveting with full curve traceability — achieved by modifying the existing riveting gun rather than replacing the process.

  • Step-by-step operator prompting through the entire riveting sequence
  • The Böllhoff riveting gun modified to expose process signals
  • Advantech acquisition cards capture the riveting curve for every joint
  • Curves stored and traceable — the data problem solved without a new machine
Approach
Retrofit
Rivet gun
Böllhoff, modified
Acquisition
Advantech cards
Output
Curve per joint

Single-operator workstation

Quick-connect coupling assembly & test workstation

A compact workstation built around a twelve-station rotary table, running two product variants with error-proofing designed in from the first drawing.

  • Camera-based mixed-part prevention between two visually similar variants
  • Interlocked poka-yoke signal chain — the next step is blocked until every prior signal is satisfied, with a separate recipe per variant
  • Servo press-fitting with vacuum part-holding and negative-pressure monitoring
  • Pneumatic precision gauging with calibration certificate and temperature compensation
  • NG parts segregated by defect class: mixed part, dimensional, press-fit
  • The same program modernized the customer's existing rotary test machine — new servo loading gantry, quick-change dial fixtures, oil-spray station, DMC verification and OK/NG offload
Layout
12-station rotary
Variants
2
Operators
1
Changeover
Minutes
3D design of the coupling assembly and test workstation

Robotic work cell

Robotic deburring cell

A fenced cell combining a SCARA and a six-axis robot to take deburring off the operator entirely, running three shifts a day.

  • Force-compliant tooling follows the burr, absorbing part-to-part positioning variation
  • SCARA handling paired with a six-axis robot for the finishing pass
  • Safety-fenced layout with operator load/unload outside the working envelope
Robots
SCARA + 6-axis
Tooling
Force-compliant
Duty
3 shifts
Material
Cast iron / bearings
Robotic deburring cell with SCARA and six-axis robots

Smart factory software

MES for machining production lines

Manufacturing execution deployed across multiple machining lines — the layer that turns machine data into something a plant manager can act on.

  • System management and production planning
  • Master data maintenance across products and processes
  • Process management tied to the actual station sequence
  • Quality data collection and analysis across the machining fleet
Scope
Multiple lines
Modules
Planning + process
Data
Quality analysis
Layer
Between ERP and machines

Your process, on this list.

Most of these started as a single station or a study before they became a line. Describe what you're building and we'll tell you where it fits.

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