Labels with RFID chips, stiff, thick materials, or sensitive functional layers make high demands on the dispensing process. However, classic labeling/processing systems can damage sensitive materials and RFID chips due to multiple deflections around small rollers. That’s where a new dispensing system with a servo drive from the Schreiner Services competence center comes into play.

The key lies in the web tension: In industrial settings, labels are typically delivered on rolls and must be peeled off the liner for the application. To do so, the label web is mechanically tensioned by slowing down the speed of the material roll and pulling the liner across a dispensing edge. To achieve a uniform web tension, three so-called dancers and several pulleys are used, but the heavy bending around the pulleys can damage a RFID chip or PCS.

Easy Does It

The newly developed dispensing system eliminates the need for pulleys. The label web is transported from the material roll directly to the dispensing edge and the surface of the label is not touched. “Instead, the web tension required for the dispensing process is generated via individually controllable servo motors enabling labeling in a reliable process—especially for sophisticated labels,” explains Michael Reineke, Head of the Schreiner Services competence center. That eliminates the risk of bending. In that way, servo-driven dispensing systems create new opportunities to reliably integrate complex functional labels in a stable process even for increasingly challenging designs.

The term “servo” comes from the Latin verb servire (“to serve”) and its first-person singular form servo, meaning “I serve.” In technology, it describes automatically controlled drives or systems that precisely respond to commands. In this case, the servo drive ensures the correct web tension.

All-in-one often sounds enticing: fewer steps, less effort. Yet sometimes it pays to deliberately split processes. That’s exactly what the team of the Schreiner Services competence center did in the case of an ultrasonic welding unit for Pressure Com­pensation Seals (PCS). An approach that noticeably enhances stability and process reliability.

In the case of many applications, the sonotrode must do not just one but two jobs in terms of ultrasonic welding of membranes: It first cuts out the membrane and then welds it onto the component. That means it must have sharp edges, which makes it prone to wear. This results in several potential sources of defects, which poses a risk especially in the case of large volumes.

That’s exactly where the new solution comes into play: It deliberately splits the previous process into two steps by using pre-cut membranes. At Schreiner Group, that step is performed on high-performance cutting machines in regular production. “In that case, the sonotrode can focus on its primary task: precise welding in a reliable process. Without the additional cutting function, its geometry remains stable and its service life clearly longer. The result is a robust, durable process with far less failure potential,” explained Michael Reineke, Head of the Services competence center.

Automatic Precision Dispensing

Another advantage of the new unit is automated handling of the Pressure Compensation Seal. While in other assembly processes involving ultrasonic welding the membranes often need to be positioned manually, a precision dispensing system takes care of that in this case. It guides the pre-cut membranes automatically and precisely underneath the sonotrode. That enhances repeat accuracy, reduces operator effort, and minimizes the risk of positioning errors in the current process.

In addition, an airflow measurement unit is directly integrated in the system. Immediately after manufacturing, it checks if the Pressure Compensation Seal reliably performs its job. Together with the sonotrode that needs to do only one job anymore and the automated “travel” of the membranes this has resulted in a solution that constantly guarantees high component quality and process reliability.

Longitudinal ultrasonic welding systems are a time-tested technology not only for joining membranes. However, up until now, only self-adhesive versions have been usable for fleece-backed membranes with high airflow. Those days are over now:

In a pioneering joint project, the team from Schreiner ProTech together with MS Ultraschall Technologie GmbH developed an innovative ultrasonic welding system for mechanically sensitive pressure compensation seals (PCS). The machine has clear advantages: high speed and precision.

In less than two seconds, the PCS sits exactly where it should. Plus, a quickchange system for tools significantly reduces production costs as well. Product Manager Adrian Marggraf is more than happy: “The basic machine is a development by MS Ultraschall while the expertise in ultrasonic membrane welding was provided by Schreiner Group’s Technology and Innovation Management (TIM) team. This project combines the professional knowledge of both parties and together we can now offer our customers an allnew all-in-one solution.” That solution is nothing short of a small revolution: Unlike longitudinal ultrasonic welding, a process in which the energy is transmitted directly in one direction, the torsional technology features indirect energy transmission through a rotary motion around the welding seam axis. That method is particularly gentle and specifically suited for mechanically sensitive membranes with high airflow. The benefits are obvious: “Especially in the automotive sector, where the components with sensitive electronics are becoming increasingly smaller and compact,” explains Marggraf, “they need proper pressure compensation.”

PCS attachment using torsional ultrasonic welding not only ensures a totally precise and extremely durable connection but also means that you may only need one high-performance membrane with high airflow instead of several classic PCS.”

Consequently, the complete package of the material and machine available from Schreiner ProTech is ringing in a new era of efficiency and quality enabling customers in the automotive engineering industry to benefit not only from a technological advantage but also from a sustainable competitive edge.

Actually, the task sounded quite simple: the application of a seal to the plastic surface of two halves of the case to prevent manipulation. But often it is the supposedly simple things that turn out to be particularly challenging. “In contrast to conventional, flat surfaces, the seal should be applied to a housing in a hard-to-reach and bent area,” explains Michael Reineke, Head of the Schreiner Competence Center Services. The team’s ambition was awakened, especially since the customer wanted to fundamentally optimize the previous, purely manual and process. The goal: improved speed and, above all, significantly higher process reliability.

To achieve this, Schreiner Group’s experts took a two-pronged approach: The development managers took care of the seal, which was equipped with various security features, in a great deal of detailed work and precise coordination, while a few rooms away they had to design an applicating machine for this special case. The material of the ink pad, which presses the seal, played just as much a role as the rotary movement required by the application angle.

It took just under half a year before the tailor-made solution was ready. The result: the fast, precise and reliable application of an individual security seal. The seal, which had to be approved in accordance with the test rules of the Federal Office for Security (BSI), now forms a complete solution in combination with the machine. “For us as a manufacturer,” explains Thomas Anderson, project manager at Stoneridge Electronics, “it is of great importance that our products enable absolutely precise monitoring of driving and rest times—and this solution makes our SE5000 even smarter. What certainly contributed to the successful implementation of the project was the trusting cooperation with all those involved at Schreiner Group and the professional customer relationship.”
The very simple order developed into an interplay of expertise and innovation, with which Stoneridge can not only strengthen its position in the market, but now also set new standards for safety and efficiency in the transport industry.

It was soon clear that the film-based solution for housing closures developed by Schreiner ProTech was a true alternative to existing variants on the market, and when the Film-Based Cover (FBC) won recognition by FINAT, the European association of the self-adhesive label industry, the team was even more delighted. Now, a little less than a year later, the Film-Based Cover scores with new functional features. Here’s a peek at “FBC all inclusive.”

Admittedly, at first glance, the small, dark box still appears to be rather inconspicuous. It’s the thing replacing a cover that packs a punch: a strong polyester film, precisely applied, and permanently and reliably bonded with the housing by means of laser welding. A lightweight and permanent closure solution that resists chemical, mechanical, and thermal stress.

But that’s not all, because the Film-Based Cover has evolved into a veritable all-in-one product: Be it as an integrated Pressure Compensation Seal, warnings, or subsequent TTR overprinting, the new Film-Based Cover provides customers with flexibility. “Our initial motivation was to offer a true alternative to the conventional injection-molded cover,” explains Markus Loris, Product Manager, Protection Films at Schreiner ProTech. However, conversations with customers soon made it clear that this product has great potential! “Due to a generic evolution,” says Loris, “we managed to realize customer wishes step by step and integrate more and more additional functions into this product.”

For customers, switching to this housing solution specifically means that Schreiner ProTech provides them with one flat component where they previously needed to use and install four individual components: a housing cover, a nameplate, an information plate, and a Pressure Compensation Seal.

The results are less space required in the production line, lower capital expenditures for manufacturing machines, cycle time reductions, and a lower administrative workload: a clear reduction of complexity that truly adds value.

Suitable uses for the Film-Based Cover include sensor applications such as those of interior space monitoring. Radar permeability, which is clearly better than that of solid injection-molded covers, increases sensor performance and so makes this solution particularly attractive. The Film-Based Cover is a perfect example showing how a smart basic idea keeps evolving and growing bit by bit. Stay tuned to learn what the next growth spurt is going to offer.

Schreiner’s solution is based on two components: the so-called Folding Frame and the Folding Frame Processing System. What makes this solution so special?

Folding Frame

Unlike variants using liquid adhesive, where long curing times often slow down the manufacturing process and the flow characteristics of the glue usually prevent one-hundred-percent precision and cleanliness of creating the adhesive bond, this variant using foam-based adhesive tapes is fast, easy, and eco-friendly. Due to the creation of a small, foldable frame version, a full-surface outer frame can be avoided, and in-process material consumption can be significantly reduced. In the case of the Folding Frame, the adhesive material is produced side-by-side in a space-saving way. The adhesive tapes remain connected at the ends to subsequently ensure tightness—a major advantage compared to conventional adhesive tape solutions.

Folding Frame Processing System

The Folding Frame Processing System is like the icing on the cake and makes this angular adhesive bonding solution truly unique: it enables absolutely precise positioning of the adhesive tapes. “At the competence center, we thought about how we could simplify the application of the tapes while ensuring high levels of precision,” says Michael Reineke from the Schreiner Services competence center, summarizing the situation. The result is a semi-automatic application system that picks up the adhesive tapes, unfolds them to create a frame, and joins the components together. That ensures high application accuracy and reproducibility. For the customer, it translates into significant time and cost savings and a reduction of potential mistakes in manual processes.

The processing system can be used whenever shapes with at least four corners exist. The Folding Frame Solution, for which a patent application has been filed, is equally efficient and versatile: “Whether it comes to precise fastening of displays,” explains Product Manager Markus Loris from Schreiner ProTech, “the equalization of irregularities or height differences, damping of vibrations, or sealing to keep out dust and splash water, thanks to its versatility and strength, the Folding Frame Solution can be used in a wide variety of markets and is absolutely in line with industry’s lightweight design trend.”

The splash water- and temperature-resistant Folding Frame Solution is not only a true alternative in the marketplace but also a good example of how Schreiner Group can deliver a product and matching processing system from a one-stop shop thanks to a well-gelled team.

So-called highly automated driving according to Level 3 has actually been possible in Germany for the past year and a half, meaning that automobiles have been allowed to travel at speeds of up to 60 km/h largely autonomously. But the decisive next step will follow at the beginning of 2023 when cars will hit the freeways at permissible speeds of up to 130 km/h. Germany is a pioneer in this regard—and Schreiner ProTech is actively involved as a provider of solutions.

It is one of the forward-looking projects in the automotive industry and the developments are awesome. What is currently happening in the area of autonomous or assisted driving resembles a small revolution. It is a huge opportunity also for Schreiner Group. “We have the good fortune to be in a position of offering solutions for the entire value chain—from pressure compensation seals to film heaters,” says Thomas Köberlein, President of Schreiner ProTech. “Naturally, knowing that we can make a crucial contribution to the further development of this new form of mobility is enormous motivation for the whole team.”

With camera systems, for example, that must be ready to perform practically at the drop of a hat. That’s a real challenge especially in winter. To enable autonomous driving in the first place, specialty solutions based on printed electronics for sensor technology are required. These functional films are extremely flat and flexible and reach temperatures of up to 150 degrees centigrade. They are also used for Radar or LiDAR systems.

Equally essential for a ride with the computerized chauffeur is trouble-free communication between the vehicles operating in the respective traffic situations. 5G antennas ensure a high communications standard. Schreiner Group’s experts have developed a total solution containing both the specially shaped functional label and the processing machine delivering reliable, reproducible, and highly precise results.

Today, an outstanding driving experience is at least equally important to car buyers as sustainability. With autonomous and connected driving the time on the road will turn into quality time. That Germany is now the first country to roll out the next speed level on Level 3 is a positive signal for the country as a business location—and further motivation for creative ideas all the way to fully automated driving.

Smaller, lighter, and simpler: That’s what components should be—not only in the automotive industry. There’s an obvious trend to “keep it simple” while the exacting demands to be met by the components continue to exist. In the form of the Film-Based Cover (FBC), Schreiner ProTech offers its customers an optimal solution.

Currently, plastic component housings are typically closed using injection-molded covers. However, those covers entail high tooling costs and require a certain amount of space during shipping as well in relation to installation.

A film-based cover as a housing closure provides a simpler solution reducing handling complexity. It features a strong polyester film that is cut to size and delivered on rolls. Its benefits are obvious: The film considerably helps save weight of the entire component—up to 85 % weight savings are possible! Lightweight and flat, the film-based solution provides a watertight and dustproof closure and withstands chemical, mechanical, and thermal stress. Consequently, a wide variety of challenging automotive applications can be implemented with it. Schreiner ProTech’s applicator system enables precision application of this substitute for injection-molded covers. Laser welding creates a permanent and reliable bond between the film and the housing.

The possible integration of pressure compensation seals is another advantage of the film-based solution. Schreiner ProTech’s total solution is rounded out by the significant cost benefits of the Film-Based Cover for customers.

Attractive alternative: Film-Based Covers are clearly lighter and flatter than injection-molded housings. In addition, they can be provided with (left) and without (right) pressure compensation seals.

Film-Based Covers can be used in various vehicle applications. Whether in electronic control units or sensor housings, the film-based components are advantageous wherever weight savings and minimal space requirements are crucial.

The customer had specified a clear set of objectives for the team of the Schreiner Services competence center: reliable sealing of sample parts with an opening seal. The challenge: the manual processing system was to function with equal precision on diverse designs and be able to apply seals around edges. The new seal applicator developed by the team is a customized solution delivering compelling results.

It is the mix of manual and automatic elements that makes this seal applicator unique. Whereas the label is automatically dispensed off the roll underneath the stamp, a worker operates the stamp manually to position the label, assisted by a guide rail ensuring that the seal always sits precisely in the same spot.

“Our subconscious mind subjectively judges the quality of a product,” explains Michael Reineke, head of the Schreiner Services competence center. “If the seal somehow sits in a different place every time and everything looks messy, we automatically have doubts about the product’s quality. However, emphasizing the outstanding properties of a product by means of the repeatably precise application of our label enhances the product’s value.” The manual and easy to use application solution was selected for cost reasons because it will initially be utilized only in low-volume production.

The development of the seal applicator took only a few weeks because Schreiner Group’s experts were able to build on previously existing versions and to create a new, customized solution quickly based on their specialized know-how. Due to the requirement that the machine accommodate designs of varying sizes, the team placed component holders on top of quick-change fixtures that are individually adapted to each component and guarantee that the closure seal always sticks to the component in the right place. This makes it possible for different components to be labeled consecutively with a flick of the wrist—quickly, easily, and very precisely.

The special characteristic of this machine is that a functional label is applied with maximum precision to a three-dimensional object at an angle of nearly 360 degrees—including functional checks using trilateral image inspection and resistance measurement.

“Rollers, dispensers, and applicators are part of our standard portfolio. But this type of processing is really rare and extremely difficult to implement,” explains Andreas Litzlbeck, project leader for automation solutions. In spite of this major challenge the machine delivers reliable, reproducible, and highly precise results in a matter of seconds—criteria to which not only customers in the automotive industry attach great importance.

About one year passed between the initial idea and the final product. The heart and soul that was put into this entire project becomes apparent when Michael Reineke, head of the Schreiner Services competence center, passionately describes it as a “technical gem”: “I’m delighted that, thanks to our know-how, we’ve been able to supply not only the specialty label but also the complex processing machine for it. Implementing even the smallest modification loop in an innovation project and shaping it creatively and constructively always poses a challenge—but one that we’re pleased to take on.