Realis Technology

What We Deliver

Five ways a project takes shape

Most enquiries arrive as one of these. Each is something we have built and shipped — the examples under each are real systems, not capability claims.

Turnkey Line

Assembly & Test Lines

Step 3 · Full line

A complete production line from first operation to line-off — stations, transfer, testing, traceability and ramp-up, delivered as one program.

  • 30+ linked stations with automated transfer and buffering
  • In-process and end-of-line testing built into the line, not bolted on
  • Serial-level traceability written back to your MES at every station
  • Line layout, takt balancing and operator interface design

Built: Electric compressor line — 25 s takt, 18 operators per shift. Conventional compressor line — 12 s takt, 33 operators, nine linked equipment groups. HVAC box assembly — 23 stations at 90 s takt with four in-line test machines, and the same program delivered to a plant in Mexico.

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Electric compressor production line
Work Cell

Robotic Work Cells

Step 1–2 · Single cell to line section

A self-contained automated cell that takes over one operation — machine tending, finishing, handling or assembly — and runs it three shifts a day.

  • Robot loading and unloading for CNC machine tools, single or multi-machine
  • Automatic polishing and deburring with force-compliant tooling that follows the burr
  • Vision-guided pick and place, SCARA, delta and 6-axis cell design
  • Safety-fenced or collaborative layouts sized to your floor space

Built: A robotic deburring cell combining a SCARA and a 6-axis robot with force-compliant tooling, running three shifts a day.

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Robotic deburring cell with SCARA and 6-axis robots
EOL Test

End-of-Line Test Stations

Step 1 · Standalone station

A purpose-built station that proves the product works before it ships — the most common way customers start with us, because it drops into an existing line.

  • Leak testing — helium, pressure decay and vacuum methods
  • AI-driven NVH testing: acoustic and tri-axial vibration, no soundproof room required
  • Electrical validation — insulation, hi-pot, functional cycle and start-up testing
  • Pneumatic precision gauging with calibration certificate and temperature compensation
  • Pass/fail data logged against every serial number

Built: AI-based NVH test equipment that runs on the factory floor without an acoustic room, judging NG/OK in real time. Helium charging and leak testing, motor performance verification, insulation and hi-pot stations running as part of the compressor line.

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Automated test and assembly line
Tooling

Tooling & Fixture Packages

Step 1 · Contained scope

Precision tooling, fixtures and single-operator cells — engineered alongside the automation that uses them, with error-proofing built in from the start.

  • Quick-change tooling — variant changeover in minutes, not shifts
  • Interlocked poka-yoke signal chain with a separate recipe per variant
  • Camera-based mixed-part prevention between similar products
  • Defect-classified NG segregation and reporting

Built: A single-operator quick-connect coupling assembly and test workstation built around a 12-station rotary table: two variants, vision anti-mix, servo press-fitting with vacuum holding, pneumatic gauging.

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3D design of a coupling assembly and test workstation
Retrofit

Retrofit & Modernization

Step 1 · Existing equipment

Upgrading a machine you already own — new tooling, new handling, new data — instead of replacing a line that still has years left in it.

  • New servo loading gantries and quick-change dial fixtures
  • Added process stations — oiling, marking, inspection
  • Data acquisition retrofitted to existing equipment, with curve traceability
  • Reuse of qualified hardware wherever it still performs

Built: As part of the coupling workstation program, the customer’s existing 12-station rotary test machine was modernized — new servo loading gantry, quick-change dial fixtures, oil-spray station, DMC verification and OK/NG offload. Separately, car tailgate riveting equipment was retrofitted with data acquisition and full curve traceability.

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12-station rotary test machine with new servo loading gantry
Software

Smart Factory Software

Delivered with the equipment

MES, WMS, MDC and DNC — the layer between your ERP and the machines on the floor, so a line we deliver reports the same data as the rest of your plant.

  • Production planning, monitoring, quality and equipment management
  • Machine data collection with live fault alarms
  • Warehouse, packaging and logistics management
  • Mobile dashboards and shop-floor digital signage

Built: MES deployed across multiple machining production lines — planning, process management and quality data analysis.

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Processes We Automate

What goes inside the systems

These are the operations that make up the stations above — the reason a line holds its cycle time and its quality numbers.

Servo press-fitting with force/displacement curvesMulti-spindle tightening with torque loggingRiveting with full curve acquisitionShrink-fitting and thermal assemblyRotor magnetization and flux verificationHelium, pressure-decay and vacuum leak testingAI-based NVH classificationInsulation and hi-pot validationAdhesive, sealant and thermal-paste dispensingOiling and greasing with volume controlDeep-learning surface defect detectionLaser marking with DMC verificationPneumatic precision gaugingVision-guided handling and assembly verification

Not sure which shape fits?

Describe the process — product, volumes, what's manual today. We'll tell you whether it's a cell, a station, a retrofit or a line, and what it takes to get there.

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