Brainware Solutions GmbH
About us
Brainware Solutions GmbH is a special machine manufacturer from Chemnitz specializing in assembly and quality inspection equipment. Since 1997, our company has stood for high-end applications in industrial image processing and multi-sensor technology in the field of automation and testing technology. Thanks to our many years of know-how in integrating our systems into a wide variety of manufacturing processes, we have developed into an automation specialist and full-service provider. Our competencies lie in industrial image processing, cable harness testing, assembly inspection, 2D and 3D measurement, contour testing, surface inspection, type recognition, function control, but also in the implementation of robot applications as well as in automation, in testing technology and in special machine construction.
Products & services
End-of-Line Tester Sensors / Sensor Electronics (Example)
Modern sensor technology has to meet a multitude of requirements. In addition to validating the basic sensor readings, tolerances on the component must be determined, sealing surfaces and sealing media checked or wobble amplitudes determined. Modern sensors are equipped with integrated evaluation circuits. Our systems allow us to simulate the installation situation, evaluate the measured values in this standardised environment and programme the sensor electronics accordingly.
End-of-line Tester for Castings / Cast Parts (Example)
Castings have developed into real high-tech components. However, series production and faster production methods increasingly require the use of intelligent testing systems, especially for preparing and checking further processing steps. For example, we have developed testing devices that determine the casting distortion of a component at up to 30 positions with an accuracy of 10 µm in just one testing travel. Our customers now use these devices instead of conventional measuring systems. The number of test points can even be extended depending on the application. In addition, our systems are also used after machining, for example for the surface inspection of machining surfaces or for the determination of position deviations of boreholes and threads. Of course, our testing units can also be integrated into existing line concepts.
End-of-Line Tester for Printed Circuit Boards PCB (Example)
Due to the size of the workpieces to be tested and the often low cycle times, quality assurance in the area of printed circuit boards places high demands on the testing technology. There are many different quality characteristics. Our services include functional tests, such as paired or simultaneous multi-contact continuity tests or activation of functional components, or in-circuit tests, such as the determination of a wide range of conductor path characteristics. In addition, optical tasks such as measuring contact widths and SMT or THT solder menisci can be realised. Of course, visual and electronic inspections can also be combined in many cases. Our solution will be tailored to your requirements and your process, for example as an inline system, as a stand-alone system or as a rotary indexing table. As an independent software developer, our strength lies particularly in the creation of individual user programs. We also offer interfaces to common laboratory environments such as LabVIEW or DASYLab.
End-of-line tester for automotive door modules / door systems (Example)
Door systems are complex mechatronic assemblies. Automobile manufacturers place high demands on quality assurance and thus present their suppliers with increasing challenges. We have established ourselves as a reliable supplier in this segment and have already implemented the following tasks, among others: - Assembly tests including assembly control - Direct control of pure power motors or electronic motors via LIN/CAN - Testing of motor current consumption and driver travel time, optionally with application of a preload - Detection of winding errors and contacting driver cables, both optically and electrically - Determination of actuating forces - Testing of lock functions - Testing and parameterisation of electronic parts - Approaching the delivery position - Spare parts production without window motor - Automatic contacting for door systems without cable set - All tests are also possible on an inline basis
End-of-Line Tester for Automotive Seats (Example)
Modern vehicle seats are complex mechatronic systems with a large number of sensors and actuators. We plan your individual test sequence with you and help you with the following tasks: - Parameterization and testing of servomotors to personalize the sitting position, for massage functions or for control of air flow - electrical testing of seat heating, seat cooling and seat ventilation - Function test of buttons and switches - Check of seat occupancy detection - Completeness check of the vehicle-specific components - Quality inspection of covers and seams - Completeness check for textile accessories or finishes such as labels, embroidery, impressions, etc. - Documentation of the delivery status Depending on your needs and customer-specific requirements, we work with inline camera systems, stand-alone devices or fully automatic blind auditing systems with extensive assembly tests.
End-of-line tester for relays in railway control technology
Interlockings in railway control systems are highly sensitive systems on whose absolute precision and reliability human lives depend. Contrary to the general trend, proven and more robust analogue technology rather than electronics is used to control the systems. The switch between analogue technology and electronics is the multi-contact high-voltage relays used here. We are the only supplier on the market to offer systems that both enable the synchronisation of each individual switching contact and, at the same time, thoroughly test the relays in the high-voltage range. This project presented us with enormous challenges, both in terms of safety for the operator and the sometimes extreme complexity in a very small installation space - and we were able to solve both.
Screwing Stations / Screw Assembly Workstations
Brainwares screw assembly workstations or screwing stations - tailor-made for your products: - Designed as gantry, stand and multi-spindle system - Can be individually adapted to your production process, e. g. through integrated storage and shelving areas or through the integration of further processes. - Misassembly is reliably excluded, e. g. by electrical testing, cross-checking with multi-coloured cable coding or visual sensor technology - Can be equipped with individual insertion tools including tool management - Support of all common screwdriver manufacturers such as Desoutter, Deprag, Atlas Copco and others
Assembly Stations / Assembly Tables and Fixtures
When assembling cable harnesses with holders and guides, there are two main aspects to be considered: precise dimensioning of the components among each other and the correct assembly. Our assembly tables and fixtures ensure high quality! - From the individual fixture to complex assembly tables with integrated additional queries, e. g. dimensioning, presence of attachments (clips, connectors, cable ties...), locking queries, taping and others. - Expandable to include leak tests and fibre optic tests - Reliable function over the model’s entire life due to durable and solid construction - All systems are modularly expandable in terms of software and hardware
Assembly stations for High-voltage (HV) charging sockets and adapters
Despite international standards and increasing quantities in the field of e-mobility, there is still a high diversity in the design types of charging sockets. Benefit from our experience in the development and optimisation of flexible cross-platform assembly workstations: - Brainware assembly systems consist of a modular base system and interchangeable fixtures tailored to the task. - Using the modular construction kit, you can choose between the following features: - With or without screw technology? - Screw gantry, screw stand or handheld screwdriver? - Automatic screw feeding system? - Screw separator, with or without removal monitoring? - Cable tie tools with monitoring? - Contact modules for continuity testing? - Hand presses for joining components? Due to our many years of experience, we are familiar with the special features and specific requirements of common charging socket manufacturers, such as Mennekes, Phoenix Contact, TE Connectivity, Yonggui, Amphenol or Aptiv, and can provide you with competent support in evaluating the assembly instructions and identifying crucial documentation steps.
Assembly inspection systems for power distribution / load distribution
Load distributors pose a challenge in terms of inspection technology due to their individual, end-customer-specific assembly variants and the various error patterns. Using basic systems that have been optimised over many years, we create your individual solution with the following features: - Customer database-controlled testing in batch size 1 - Object-specific test functions (e. g. colour, labelling, installation direction) for a wide variety of attachments such as fuses, relays, connectors, fuse pullers, etc. - Integrated plug-in depth check for correct assembly, both by tactile and visual means - High recognition value due to sophisticated operator guidance - Plug-and-play operation is possible in many cases - In addition to a large number of already integrated solutions, we are also happy to adapt our software to your new requirements at any time. - Of course, it is also possible to test several load distributors in one system.
Nanocontact and nanoplug testing systems (e.g. for airbag contacts)
Conventional testing of the assembly of nanocontacts (airbag net) using the push-pull method requires a lot of time and personnel, is prone to errors and cannot be documented. We have taken up this challenge and developed a testing system based on camera detection. In doing so, we have achieved the following objectives: - Significant reduction of the cycle time, testing a connector with 140 contacts takes approx. 25 seconds (including evaluation). - Parallel detection of other defect patterns is possible without any negative influence on the cycle time, e. g. deformation of pin contacts or damage to the contact housing. - Tests can be repeated and documented - A statistical evaluation of the frequency of different defect patterns is carried out for each specific position and thus enables an evaluation of the pre-processes.
Intelligent Industrial Camera vCheck® Cam
The intelligent camera vCheck® Cam combines the compact dimensions of an industrial camera with the intelligence of the image processing and automation software vCheck® from Brainware Solutions GmbH. Complex tests of assembly steps can be carried out directly at the assembly workstation. Management is simple and straightforward via the network using the vCheck Manager software user interface. A large number of interfaces make it possible to integrate the intelligent camera into existing networks. Application areas - Quality checks directly at the assembly workstation to identify and avoid incorrect assemblies early on in the value chain - Supplementary quality checks to the end-of-line test - Use at manual workstations - Tests in the line before or after function modules Advantages - Compact dimensions and small footprint - Robust, industrial-grade aluminum housing - Proven vCheck® image analysis integrated with the vCheck® Smart software with analysis functions - Simple and easy to administer via the vCheck® Manager - Fast uncomplicated installation and administration - Easy integration into existing line controls or shop floor networks - Expandable with I/O modules, various lighting or output screen - CMOS image sensors
LED lighting for industrial image processing
Brainware LED lighting to support industrial image processing was developed when conventional products were not suitable for the respective application. Very often a gap in the market was filled for which there were no solutions before. All Brainware LED lighting is characterized by compact dimensions with an absolutely high light output. Great importance is attached to absolute industrial suitability and corresponding robustness. Many of the components are equipped with a sturdy aluminum housing. Examples - LED area lights with large or small spot - LED area lights with clear or diffuse reflected or transmitted light - Ringlichter / Radiallichter mit klarem oder diffusen Innenlicht - usw.
Digital signal collection modules bwSensorLink
bwSensorLink are signal collection modules for monitoring and linking incoming sensor signals. The link provides a signal that is "AND-" linked from all inputs. The output is switched when all inputs receive a high signal.
Digital input/output modules bwDIO
The Brainware bwDIO modules are multifunctional controllers and can be used both as digital I/O modules for PC programs or as compact stand-alone PLCs for control, regulation and test applications. Examples: - Digital Input/Output Module bwDIO 8/8 USB - Digital Input/Output Module bwDIO flex24 - Digital Input/Output Module bwDIO mini - Analog/Digital Input/Output-Module bwHK USB
Hand presses with integrated quality inspection checks
HAND PRESSES Our semi-automatic hand presses for component assembly contain a lot of features that can improve production processes and ensure the high quality of your products. In addition to the actual press, the system accommodates a large number of sensors, depending on your application, which carry out an integrated quality inspection check during the pressing process. All sensory, haptic, electrical, electronic or other test methods can be integrated depending on your needs. FIXTURES / WORKPIECE HOLDERS There are also no limits to flexibility when it comes to workpiece holders. Even if you want to process not just one, but several workpieces in one workplace, this is no problem. Depending on the application, the hand press can be equipped or expanded with one or more fixtures / workpiece holders that are controlled manually, semi-automatically or completely automatically. The fixtures / workpiece holders are standardized and can therefore be easily exchanged (even between different workplaces). CONNECTION The further processing of sensory data for evaluation and the connection to your databases or your operational software is also possible. And of course the hand press can be operated stand-alone as well as part of a machine or an entire production line. APPLICATION EXAMPLE For example in the field of pre-assembly of busbars.
vCheck® ConTest - test module for safety-sensitive connectors
With the vCheck ConTest® test module, safety-sensitive connectors (e.g. airbag plugs) can also be checked in the mini or nano range without contact for faultless pins and latches. The vCheck® ConTest test module replaces the conventional, error-prone manual push-pull test method. Transparent and documentable test results ensure traceable product safety, especially where there are high quality requirements and the protection of health and integrity. In addition, the non-contact inspection is more efficient in the production process. Thanks to its compact dimensions, the vCheck® ConTest test module can be used flexibly and universally as a stand-alone solution or as an integral part of an assembly and test workstation.
compact.UNI - modular assembly and testing workstation
Flexibility and modularity are challenges that manufacturing companies have to face more and more in the medium and long term. Our modular system compact.UNI offers the possibility to react to changing requirements individually, but nevertheless standardized. How can you benefit from it? - Thanks to the interchangeable fixtures, several products can be assembled on one system. This ensures that the system operate at full capacity at almost 100% and reduces energy costs and expenses for employee training. - The life cycle of the systems is increased, since systems can be quickly reconfigured even when changing models and can therefore be used longer and more flexibly. - Compared to highly specialized special machines, a well thought-out selection of function modules allows us high availability coupled with short delivery times.