Special-purpose machinery, assembly systems and test technology for assembly and production automation - development, manufacturing and commissioning from a single source.
stepp Fabrikautomation und Steuerungsbau GmbH & Co. KG
32689 Kalletal (Erder) · 32609 HüllhorstNew on Amplifa
About stepp Fabrikautomation
stepp Fabrikautomation und Steuerungsbau GmbH & Co. KG develops and manufactures special-purpose machines, assembly systems and test technology for assembly and production automation. The portfolio includes rotary-dial assembly machines, transfer systems, robot cells, industrial welding and forming technology, precision tube processing machines as well as test benches for torque, force and vibration measurement. The range is complemented by test technology for leak tightness, flow, electrical and optical inspections as well as series products such as pick-and-place units, servo rotary grippers and welding machines. All value-adding steps - engineering (3D CAD), control cabinet construction, in-house machining production with around 20 machine tools, assembly and commissioning - are carried out in-house. The main field of application is the automotive supplier industry, alongside the capital and consumer goods industries. The company was formed in 2001 from the merger of the design office MBE-Maschinenbau Ruprecht (1997) and the engineering office ibo GbR (1995) and is based at the Kalletal (Erder) and Hüllhorst sites.
- Site
- Kalletal (Erder)
- Processes
- Special-purpose machinery / assembly automation, Rotary-dial assembly machines, Transfer systems, Robot cells, Resistance welding (projection welding, spot welding, seam welding, hot staking), Automatic gas-shielded welding (TIG and MIG/MAG), Friction welding, Laser welding
- Materials
- Steel (heat exchanger tubes), Precision steel tubes, Metal fleece, Cellasto (polyurethane elastomer, damper springs), Plastic (pulley blocks), CAD/CAM machining production (milling, turning, grinding), Automatic gas-shielded welding, Resistance welding (projection, spot, seam welding, hot staking)
- Certificates
- Process monitoring (force/displacement), Image processing / optical inspection, Data acquisition DSC-SQL
- Founded
- 2001
- Industries
- Automotive supplier industry, Capital goods industry, Consumer goods industry
- 01
Requirements analysis and engineering (3D CAD)
- 02
Design
- 03
Control cabinet construction
- 04
Machined parts production (CAD/CAM)
- 05
Machine building and assembly
- 06
Commissioning at the customer
- 07
Maintenance, remote maintenance, modernization
Materials and Processes
CAD/CAM machining production (milling, turning, grinding)
In-house production of individual parts for special-purpose machines and test benches on around 20 machine tools.
Automatic gas-shielded welding
Integrated welding stations in forming and welding systems.
Resistance welding (projection, spot, seam welding, hot staking)
Industrial welding processes with force and displacement monitoring of the welding parameters.
Friction welding and laser welding
Joining processes, among others, for the fully automatic valve assembly and test system.
Precision tube processing (drawing, expanding, deburring, notching)
Rotary-dial processing of precision steel tubes, among others for seat belt restraint systems and carburetors.
Rolling force up to 2000 kN
Rolling mill for forming rectangular tubes, max. torque 70,000 Nm.
Control systems DSC-SQL / Industry 4.0
Vertical information technology integration with data acquisition and process monitoring.
Locations
Kalletal (Erder)
DEHeadquarters Engineering / Manufacturing, Industriestr. 2
- Part weight / size
- Workpieces up to 3500 kg (milling, length 3500 mm)
- Materials
- Steel, plastic, metal fleece
- CNC machining centers Wemas 1000 and 750
- Norte V6 3500 CNC machining center
- Deckel FP 4TC and FP 4A
- Wemas CNC lathe 1500
- IMA conventional lathe
- ABA surface grinding machine
- Zoller tool presetter
Hüllhorst
DEAdministration / Control cabinet construction site, Brinkhofweg 11
Machined Products
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Special-purpose machinery / assembly automationAssembly | – | – | – | – | – |
| Rotary-dial assembly machinesAssembly | – | – | – | – | – |
| Transfer systemsAssembly | – | – | – | – | – |
| Robot cellsAssembly | – | – | – | – | – |
| Resistance welding (projection welding, spot welding, seam welding, hot staking)Joining | – | – | – | – | – |
| Automatic gas-shielded welding (TIG and MIG/MAG)Joining | – | – | – | – | – |
| Friction weldingJoining | – | – | – | – | – |
| Laser weldingJoining | – | – | – | – | – |
| BendingForming | – | – | – | – | – |
| Punching / piercing / trimmingForming | – | – | – | – | – |
| Rolling (rolling mill for rectangular tubes)Forming | – | Tube length up to 6 m | – | – | – |
| Swaging and rivetingJoining | – | – | – | – | – |
| Press-fittingJoining | – | – | – | – | – |
| JoiningJoining | – | – | – | – | – |
| Precision tube processing (drawing, expanding, deburring, notching)Forming | – | – | – | – | – |
| Pneumatic testing (leak tightness, flow, back pressure, leakage testing)Testing | – | – | – | – | – |
| Electrical testing (resistance, switching time)Testing | – | – | – | – | – |
| Optical testing (contour checking, color queries, data matrix code, image processing)Testing | – | – | – | – | – |
| Test bench construction (shaker test benches, torque measurement, multidimensional forceTesting | – | – | – | – | – |
| Marking / labelingAssembly | – | – | – | – | – |
| Cutting / milling and cutting of Cellasto springs (NC-controlled)Plastics | – | – | – | – | – |
| Parts production / machining (milling, turning, grinding)Machining | – | – | – | – | – |
| Design / engineering / control cabinet construction (CAD/CAM, NC programming)Engineering | – | – | – | – | – |
9 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| CNC machining center | Wemas 1000 | – | 1000x600x660 mm, table 1300x600 mm, workpiece weight 800 kg, 20 tool stations, 8000 1/min | – | Kalletal (Erder) |
| CNC machining center | Wemas 750 | – | 750x500x500 mm, table 1000x500 mm, workpiece weight 600 kg, 20 tool stations, 9000 1/min | – | Kalletal (Erder) |
| CNC machining center | Norte V6 3500 | – | 3500x750x500 mm, workpiece weight 3000 kg, 40 tool stations, 4000 1/min | – | Kalletal (Erder) |
| CNC machining center | Deckel FP 4TC | – | 560x500x450 mm, table 900x530 mm, workpiece weight max. 540 kg, 20 tool stations, 3150 1/min | – | Kalletal (Erder) |
| CNC milling machine | Deckel FP 4A | – | 560x500x450 mm, table 900x530 mm, workpiece weight 540 kg, 4000 1/min | – | Kalletal (Erder) |
| Surface grinding machine | ABA | – | 700x500x400 mm, magnetic chuck 700x500 mm, workpiece weight 150 kg | – | Kalletal (Erder) |
| CNC lathe | Wemas 1500 | – | Turning length 1500 mm, Ø over bed 600 mm, Ø over carriage 250 mm, 2400 1/min, workpiece 350 kg | – | Kalletal (Erder) |
| Conventional lathe | IMA 1500 | – | Turning length 1500 mm, Ø over bed 420 mm, Ø over carriage 300 mm, 2100 1/min, workpiece 350 kg | – | Kalletal (Erder) |
| Tool presetter | Zoller PC-based | – | – | – | Kalletal (Erder) |
Additional services
Quality
Quality assurance is carried out through in-process inspections integrated into the systems (force, torque and displacement monitoring, image processing, length measuring systems) as well as machine and operating data acquisition. The test technology covers pneumatic, electrical and optical inspection methods with data matrix code, marking, sorting and OK/NOK separation.
| Evidence | Kalletal (Erder) | Hüllhorst |
|---|---|---|
| Process monitoring (force/displacement) | ||
| Image processing / optical inspection | ||
| Data acquisition DSC-SQL |
History
- 1995
Foundation of the engineering office ibo GbR
- 1997
Foundation of the design office MBE-Maschinenbau Ruprecht
- 2001
Foundation of stepp Fabrikautomation und Steuerungsbau GmbH & Co. KG through the merger of both offices; purchase of a production hall and acquisition of machining NC machines in Kalletal-Erder