Brochure Istituz08.qxd:Layout 1

one global company
INDEX
www.comau.com
2
PG. 04
History
PG. 06
Comau activities
PG. 08
Engineering
PG. 10
Injection Moulds
PG. 11
Dies
PG. 12
Powertrain Machining
& Assembly
PG. 14
Body Welding
& Assembly
PG. 16
Robotics
PG. 18
Laser Technologies
PG. 19
Aerospace
Production Systems
PG. 20
Service
PG. 21
Worldwide
presence
ABOUT COMAU
technology for
industrial automation
Comau is a global supplier of industrial automation systems and services mainly for the automotive
manufacturing sector.
Over the years, by acquiring and integrating other companies, Comau broadened its presence all over
the world, becoming the ideal partner for the automotive industry in developing solutions for all
industrial production programs.
Comau's utmost goal is Customer satisfaction, anticipating needs and exceeding expectations. The
continuous improvement of products, processes and services, through the application of the most
advanced innovative technological solutions, allows Comau to contribute to its Customers'
competitive advantage.
3
HISTORY
milestones
1990 s
1970 s
The origin of Comau dates back to the “COnsorzio
Comau do Brasil Ind e Com. Ltda and Comau
MAcchine Utensili ” established to gather all com-
Argentina S.A. are set up to operate on the Mercosur
mercial activities of the Turin area manufacturers
market for all Comau Business Units.
involved in the technological equipment of the Tolyatti
AVTOVAZ plant in Russia.
Comau Deutschland GmbH guarantees a local presence in the German market for all Comau Business
These companies merge into a limited company
Units.
named Comau Industriale S.p.A., later re-named
Comau S.p.A.
Comau Service is set up with the mission to supply
full maintenance services, from engineering to plant
management, to the worldwide automotive market.
1970 s
1980 s
1980 s
Comau Productivity Systems Inc., later re-named
The sheet metal dies production plant of Comau
Comau North America, is established to develop com-
Poland Sp.z.o.o., located in Tychy, begins to operate
mercial and industrial activities in North America.
and later expands its activities to include maintenance
services.
Comau S.p.A. takes over Berto Lamet (sheet metal
dies) and U.T.S. (product and process engineering).
Comau takes over Renault Automation S.A. (France),
Berto Lamet takes over TEA, a company specialized in
specialized in engineering, metalcutting, mechanical
injection moulds manufacturing and Mecaner S.A. in
assembly and body final assembly. The “body systems”
Bilbao (Spain), with consolidated experience in sheet
and “welding guns” activities of the French company
metal dies manufacturing.
Sciaky S.A. are also acquired.
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The Companies are subsequently merged and renamed Comau France S.A.
4X
2000 s
Progressive Tool and Industries Co.(PICO) and affili-
Comau continues to strenghten its growth strategy in
ate companies worldwide are taken over and re-named
Europe and Asia by establishing subsidiaries in China,
Comau Inc.
Romania and Russia.
Comau (Shanghai) Automotive Equipment Co. Ltd., in
These acquisitions contribute to create the major
Shanghai is set up to focus on development in the
worldwide supplier of production systems for automo-
Chinese market, mainly its body welding and power-
tive industry, providing product and process engineer-
train systems business.
ing, body systems and dies, powertrain, robotics and
handling systems, maintenance services.
Comau acquires two companies operating in the automotive product and process engineering area,
Comau Estil (UK) operates through its local offices
German-Intec GmbH and the Romanian Team
principally in the body systems area.
Resources România re-named Comau România S.A.
2000 s
1990 s
Comau India Pvt. Ltd. in Pune begins to operate in the
Comau Russia S.R.L in Moscow focuses on import-
local market, Comau South Africa Pty. Ltd. carries out
export activities to facilitate the Comau Group's pres-
important activities of body systems and dies.
ence in Russia.
From 2006 Comau reorganized into four Business Units:
• Engineering, Injection Moulds & Dies
• Body Welding & Assembly
• Powertrain Machining & Assembly
• Robotics & Service
The offering of full services, from product engineering
to maintenance activities, and the integrated global
organization allow Comau to compete in the continuously evolving automotive global market.
5
ACTIVITIES
many products,
one company
Engineering
Injection Moulds
Dies
Powertrain
Machining & Assembly
From the Idea to the Product
To the automotive Customers worldwide, Comau
offers its proficiency as System Integrator and its
complete engineering solutions, from product
development to manufacturing, from assistance to
the production start-up phases, up to equipment
and plant full maintenance activities.
The key to simple but effective industrial automation
Comau automation systems are designed to make product manufacturing process simple, “lean” and
cost-effective.
In addition to state-of-the-art engineering technology and factory-floor tested hardware and software, Comau
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builds its products through long term experience, unmatched market expertise and the results of continuous
R&D activities, while Comau experts provide total Customer support in finding the single or global solution to
all manufacturing requirements.
This explains why all major automotive manufacturers currently use Comau systems and machinery at
6X
Body Welding &
Assembly Systems
Robotics
Aerospace Production
Systems
Maintenance &
Engineering Services
facilities in Europe, America and Asia and also why large and small companies all over the world,
operating in a vast range of different sectors, have chosen Comau industrial automation solutions.
Simple, customized automation systems
Even the most highly complex automation system, the most complete production line and the most
sophisticated machinery must be user-friendly, economic to handle, versatile and capable of
producing different components with cycle times and volumes changing in accordance with market
requirements.
7
ENGINEERING
integrated solutions
From Concept to Manufacturing
For over 60 years Comau Engineering, Injection Moulds & Dies has been supplying quality engineering
services and production tools mainly to the automotive industries.
The ultimate goal of Comau Engineering is the management of full turn key vehicle projects, to cope with the
highly competitive factors which characterizes the automotive sector.
On the virtual time to market (TTM) flow, a wide range of activities characterize the Engineering business,from
style feasibility to projects platforms management.
Product Engineering
Comau Product Engineering has the competence to develop turn-key projects for complete vehicle.
Starting from style feasibility and concept design, any kind of product development activities can be
carried out through master section definition, 3D and 2D studies, virtual validation, DMU, CAE, CAPE and
CAT assessments up to prototyping full BIW and complete cars for road and bench testing.
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Technical areas of core competence are:
8X
• Body
• Lay-out and Packaging
• Underbody
• Gearbox and Driveline
• Chassis
• Engine Installations and Modifications
• Bumpers
• Dashboard
• Brake system
• Seats
• Suspensions
• Internal and External Trims
Process Engineering
Process Engineering is developed simultaneously with Product Engineering to optimize timing, cost of the
project and evaluation alternative solutions.
All the Process Engineering activities are carried out in different areas as body welding, machining, final
assembly, mechanical assembly, closures, die-casting, functional tests and trims (bumper/dashboards/seats),
with intensive use of virtual tools.
We design and develop innovative solutions for automotive related processes in body and powertrain
process engineering and aircraft related manufacturing processes.
Program Management & Central Engineering Department
The Central Engineering offers core competences in:
• Product Simulation & Testing
• Methodologies
• Concept & Benchmarking
• Product & Process Ergonomics
• Process Simulation
• Cost Engineering
• PDM-PLM
• Planning & PM methodologies
• Advanced Engineering
9
INJECTION MOULDS
injection moulds
Founded in 1945 in Turin as small firm, Comau Injection Moulds became part of the Comau Group in 1989.
Comau has led the process of industrial innovation and renewal of production and materials technologies,
step by step, transforming a hand-crafted type of production into a highly specialized technique.
Comau Injection Moulds products include:
• Tools for the injection moulding of thermoplastic materials for complete instrument
panels, bumpers, fenders, door panels, interior and exterior trims
• Tools for compression moulding of cab external parts and structural elements
• Tools for magnesium parts, cross car beams and seat structures
Comau Injection Moulds is also deeply involved in pilot and prototype tooling and it is focused on managing
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complete projects including the supply of welding machines, gauges and assembly nests.
10
DIES
sheet metal dies
Comau Sheet Metal Dies is a supplier of sheet metal stamping tools for the automotive industry.
Utilizing the component build process Comau can support the manufacturing and try out of large, medium
and small automotive dies.
Comau expertise is particularly relevant in:
• Design and production of large-size dies for body components, in particular body-sides,
roofs and closures for sheet metal and aluminium parts
• Complete metal forming systems (drawing, blanking, hemming) for doors and closures.
11
POWERTRAIN
MACHINING & ASSEMBLY
delivering endurable
performance
At Comau Powertrain Machining & Assembly we focus on technology delivering value to our Clients.
Our products, Machining Centers & Systems, Assembly and Testing Systems, ensure Quality and Productivity
to the highest degree for machining, assembling and testing of:
• Engines
• Transmissions
• Crankshafts
or other components.
At Comau Powertrain M&A we follow our Customers along the whole manufacturing chain with three
product lines:
Machining Centers and Systems for metalcutting of engine and transmission components
Assembly Systems: module based assembly cells for engines, transmissions or components
Testing Systems: hot, cold and in-process test stands
Our machine portfolio is designed to cover the whole range of our Customers products in type (heads, blocks,
crankshafts, transmission housings) size and material (aluminium, cast iron, CGi, etc).
Through the experience of engineering and delivering equipments and processes to the Automotive Industry,
our solutions can meet the demanding requirements in flexibility and production scalability together with
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simplicity and reliability.
12
The competence to develop transfer lines or to integrate them into hybrid solutions completes our
technological offer.
Machining Modules
Urane
Linear motors based machines, at the third generation, ensuring the utmost performances
1g
Ball screws based high speed machines
MT
Large and powerful machining centers for heavy duty operations
Crankshaft
Milling, broaching and dynamic balancing machines to ensure quality throughout the Crankshaft production
process.
SmartDriveComau
New family of machining centers from Urane and 1g experience, offering modular configuration to cope with
different market requirements.
Assembly Modular Solutions
We engineer, manufacture and install systems for the assembly of engines (cylinder head, short block, long
block), transmissions (automatic, manual, CVT) and components, as well as of ancillary equipment (valve
seats and guides, plugs, caps) within the metalcutting lines.
Our assembly systems are based on standard modular solutions (SmartCellComau and SmartBoxComau).
Synthesis of the Comau knowledge, the assembly modules are characterized by the same structure and
allow to locate different specific tools for cylinder head and engine assembly.
Hot tests, cold tests and in-process tests complete our offer range in the assembly shop, enabling our
Customers to control and optimize the production process and to collect and analyze -in real timeproduct information.
Our competence ranges from R&D testing in the product development to supporting production start ups of
a new product, to monitoring and continuously improving the assembly processes.
13
BODY WELDING
& ASSEMBLY
developing and delivering
excellence
Body Welding & Assembly is global leader in the supply of production systems for vehicle full body, body components manufacturing and complete turn-key body shops world wide.
We support our Customers with a complete set of services ranging from concepts development, advance engineering, simultaneous engineering, process development & validation, simulations, to the supply of complete
production systems, production launch and maintenance.
The complete portfolio of Comau solutions allows us to provide the most cost effective low, medium and high
volume body welding and assembly systems in the world.
With over 50 years of experience in body shop technology we fully understand and anticipate our
partners’ needs.
Best-in-class Solutions
Template modules and standard components are available in CAD/CAE 3D libraries and can be utilized to
model and simulate the behaviour of the system as a virtual enterprise.
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We provide optimal solutions for:
14
• Body
• Closure Hemming Systems
• Underbody
• Openrobogate cells for body framers
• Body Side
• H-Gate geo systems for body sides
• Subassembly
• Agilaser
• Closure Assembly
• Robot Laser
Final Assembly
Through our extensive experience of delivering world class solutions for body shop systems, powertrain
assembly and test systems, handling, storage and distribution systems, Comau has developed considerable
expertise in the design and implementation of final assembly systems and is able to offer:
• Conveyors and material handling systems
• Automatic insertion systems for cockpits, seats, head linings, bumpers and door seals
• Automatic gluing and insertion of glasses, windscreen, rear screen, quarter light,
moon-roof, sun-roof.
• Engine to chassis marriage systems including chassis lifting and body lowering techniques
Standard Components
In developing body shops manufacturing solutions Comau BW&A utilizes standards that maximize system
efficiences, facilitate cost reduction and shorten launch time:
• Modular End-effectors and Grippers
• Belt and Cross-belt Conveyors
• Floor and Overhead Pallet Conveyors
• Lifters
• Trunions
• Power Roller Tables
• Clamps and Risers
• Turning Tables
• EMS
• Elevators
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ROBOTICS
high performance,
smart solutions
Comau, worldwide leader in the manufacturing of automatic flexible systems, always played the role of
leader in the evolution of Industrial Robotics.
Comau Robotics offers its Customers a complete series of standard robotized solutions, technologically
advanced, which are the result of continuous effort to meet its Customers' requirements.
SMART Robots
Comau Robotics is one of the worldwide leading manufactures of high
quality industrial robots. The continuous improvement of products,
processes and services, through the application of the most advanced
innovative technological solutions, allows Comau Robotics to contribute to
its Customers' competitive advantage.
SMART is the latest generation of the Comau Robots: from 6 to 800 kg of
payload with reduced overall dimensions and large working volume, high
precision of movements and positioning accuracy, high reliability and low
maintenance costs.
These new Robots are addressed to several applications like: handling and machining operations in foundry
industry, spot welding, arc welding, glueing, polishing, grinding and deburring, heavy duty palletizing and
picking operations.
SMART Solutions
Innovative SMART Robots, powerful C4G Control Unit, user-friendly TP4i Programming Terminal, a processoriented software and a complete set of accessories fully integrated to accomplish the high performance
SMART Solutions.
SMART Solutions means integrated automated solutions, innovative and reliable, easy and fast to be
installed, capable to assure highest performances.
Comau Robotics is working alongside the Customer acting as a partner in all phases of technological
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PG:
16
ROBOTICS
process, measuring up to the challenge of assuring its future growth and that of its partners.
16
SMART Services
The satisfaction of our Customers is always on top in the Comau Robotics strategy.
A complete offer of services enables Customers to maximize performances during the whole life cycle of
Comau Robotics' SMART solutions: training at Comau plants or at Customers' facilities with multi-language
sessions, on-line support through remote diagnosis and advanced tele-services, technical assistance at
Customer's works by expert technicians, spare parts stock, re-furbishment services and maintenance
programs available throughout the world.
• Spot Welding
• Machine Tending
• Polishing / Deburring
• Arc Welding
• Sealing / Glueing
• Mechanical Machining
• Laser Welding and Cutting
• Handling
• Assembly
• Press Automation
• Foundry
• Wood Machining
ROBOTICS
PG: 17
SMART Applications
17
LASER TECHNOLOGIES
innovative and competitive
solutions
Comau has developed laser remote welding technologies since several years. Our systems allow production
of cost competitive vehicles that meet environmental and safety requirements helping weight reduction and
performance improvement. Our technology is based on a remote control of laser beam through a rapid
handling of mirrors and lenses. High positioning and welding speed, extreme flexibility, system layout and
reduced maintenance costs are unique features of our Agilaser, Smartlaser, Swinglaser systems.
AgilaserTM
Thanks to the integration of the fast remote scanning head on a gantry with high dynamics, the working
volume of the remote system is enlarge in order to be able to weld big subassemblies. The high flexibility
of Agilaser makes the system able to be integrated on a lot of different production lines.
Smartlaser TM
The Smartlaser system is made by the integration of a focusing and repositioning remote laser module
with an articulated Comau robot. It performs high dynamics positioning of the laser beam in a full 3D
working volume, combined with a higher and adjustable working distance (from 750 to 1100 mm). The
optical fibre plugged into a four axes robot permits reduction of the fibre mechanical stress and an easier
offline programming.
Swinglaser TM
Swinglaser is made by standard commercial components and allows to minimize the repositioning time in a
stitches sequence on a path. This is made by the remote approach and the use of the multikilowatt solid
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state laser source with high quality.
18
AEROSPACE
PRODUCTION SYSTEMS
Aerospace
Production Systems
From Automotive to Aircraft Production Systems
Comau Aerospace Team is dedicated to serve Aircraft Industry Worldwide in Production Processes
optimization and Assembly Systems delivery.
In the last 15 years, Comau has developed applications for civil and military fields, bringing more than 30
years of automotive production experiences into aircraft sector.
Civil and Military References
Major Civil Aircraft Manufacturers called Comau to provide them with jigs, tools, and assembly lines for
their last major programs.
In Military Sector, major helicopter and aircraft Manufacturers have used Comau expertise to develop
complete processes reengineering of their final assembly production lines.
Moreover Comau Powertrain high-speed machining centers are used for aircraft parts production.
Not only Comau Aerospace Team applies strong automotive expertise in tools design, process simulation,
assembly concept, project management and maintenance, but it is also able to provide specific expertise in
riveting, drilling and sealing applications.
Comau knowledge in carbon treatment is a real strength for future worldwide aircraft programs too.
The World Wide Team
The Team is composed of aircraft production systems skilled specialists mainly located in Comau US where
the Team headquarters and R&D centre are also acting.
In Europe the team is present in Italy, UK, Germany and France and Sales support is also available in Russia
and China.
Delivering High Efficiency Solutions
Our competence ranges from production processes reengineering to assembly lines with major attention on
investment/performances ratio improvement.
Comau Aerospace Team offers a competitive platform to the Customers interested in lowering production
costs keeping in mind the challenging market trends.
19
SERVICE
a modular approach to satisfy
customer requirements
Comau Service is fully dedicated to industrial equipment maintenance, a partner you can rely on,
considering the high technological know-how level acquired during years of experience working near the
Customers: a modular service approach to accomplish Customer requirements.
Comau Service is a leader supplier of engineering and maintenance services for equipment and production
processes, ensuring competitive solutions and top quality standards.
Comau Service organization offers maintenance services customized for local conditions, providing reliable
solutions for Maintenance Engineering & Services.
Through a Global Service Contract the Customer has the opportunity to outsource all activities related to
plant and equipment maintenance;
Maintenance Engineering is the area dedicated to engineering services at high technological content,
including: predictive/preventive maintenance, maintenance systems co-design, information technology
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support, consulting activities (TPM methodology), spare parts and warehouses management.
20
WORLDWIDE PRESENCE
many cultures, one company
From its headquarters in Turin (Italy), Comau delivers expertise and assistance through its local companies,
offices and facilities anywhere in the world.
Comau meets the highly competitive and continuously evolving global market requirements thanks to the
strength of more than 30 companies able to supply either a single product or service or a highly complex
automation system.
A worldwide presence closer to the Customer
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LOCATIONS
comau locations
COMAU S.p.A.
Headquarters
Via Rivalta, 30
10095 Grugliasco - TO (Italy)
Tel. +39 011 0049111
German Intec GmbH & Co. KG
Im Riedgrund 1
74078 Heilbronn (Germany)
Tel. +49 7131 28 22 0
Fax +49 7131 28 22 400
Comau Canada Inc.
4325 Division Road Unit # 15
Ontario N9A 6J3 (Canada)
Tel. +1 519 9727535
Telefax +1 519 9720809
COMAU S.p.A.
Powertrain Machining & Assembly
Via Rivalta, 30-49
10095 Grugliasco - TO (Italy)
Tel. +39 011 0049111
Telefax +39 011 0049688
Mecaner S.A.
Calle Aita Gotzon 37
48610 Urduliz - Vizcaya (Spain)
Tel. +34 94 6769100
Telefax +34 94 6769132
Comau do Brasil Ind. e Com. Ltda.
Rua do Paraiso, 148 – 4.o andar
Paraiso – CEP 04103-000
São Paulo – SP (Brazil)
Tel. +55 11 21262424
Telefax +55 11 32668799
COMAU S.p.A.
Body Welding & Assembly
Strada Borgaretto, 22
10092 Borgaretto di Beinasco - TO
(Italy)
Tel. +39 011 0049111
Telefax +39 011 0048672
COMAU S.p.A.
Robotics & Service
Via Rivalta, 30
10095 Grugliasco - TO (Italy)
Tel. +39 011 0049111
Telefax +39 011 0049866
COMAU S.p.A.
Engineering, Injection Moulds & Dies
Via Bistagno, 10
10136 Torino (Italy)
Tel. +39 011 0051711
Telefax +39 011 0051882
Comau France S.A.
5-7, rue Albert Einstein
78197 Trappes Cedex (France)
Tel. +33 1 30166100
Telefax +33 1 30166149
Comau Estil
10, Midland Road
Luton, Bedfordshire LU2 0HR (UK)
Tel. +44 1582 817600
Telefax +44 1582 817700
www.comau.com
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22
LOCATIONS
Comau Deutschland GmbH
Hanns-Klemm-Strasse 5
D-71034 Böblingen (Germany)
Tel. +49 7031 73400
Telefax +49 7031 7340299
22
Comau Poland Sp.Z.O.O.
Ul. Turynska 100
43-100 Tychy (Poland)
Tel. +48 32 2179404
Telefax +48 32 2179440
Comau Romania S.R.L.
Oradea, 3700 Bihor
Str. Berzei nr.5 Suite E (Romania)
Tel. +40 59 414759
Telefax +40 59 479840
Comau Russia S.R.L.
Ul. Bolshaya Dmitrovka 32/4
107031 Moscow (Russian Federation)
Tel. +7 495 7885265
Telefax +7 495 7885266
Comau SPA Turkiye Bursa Isyeri
Panayır Mah. Buttim Ís¸ Merkezi
C Blok Kat 5 No:1494
16250 Osmangazi/Bursa (Turkey)
Tel . +90 0 224 2112873
Telefax +90 0 224 2112834
Comau Inc.
21000 Telegraph Road
Southfield, MI 48034 (USA)
Tel. +1 248 3538888
Telefax +1 248 3682531
Comau Pico Mexico S. de R.L. de C.V.
Av. Acceso Lotes 12 y 13
Col. Fracc. Ind. El Trébol 2º Secc.
C.P. 54610, Tepotzotlan (Mexico)
Tel. +11 52 5 8760644
Telefax +11 52 5 8761837
Comau Argentina S.A.
Ruta 9, Km 695
5020 - Ferreyra
Córdoba (Argentina)
Tel. +54 351 4503996
Telefax +54 351 4503909
Comau SA Body Systems (Pty)
Hendrik van Eck Drive
Riverside Industrial Area
Uitenhage 6229 (South Africa)
Tel. +27 41 9953600
Telefax +27 41 9229652
Comau (Shanghai)
Automotive Equipment Co., Ltd.
Pudong, Kang Qiao Dong Road
Nr. 1300
Block 2 - Kang Qiao
201319 Shanghai (P.R.China)
Tel. +86 21 68139900
Telefax +86 21 68139622
Comau India Pvt.Ltd.
26/A/1, Kondhwa Budruk
Pune - 411048
Maharashtra (India)
Tel. +91 20 56780369
Telefax +91 20 56002865
Progetto grafico: Frenda Advertising (Torino) - Printed in Italy
Comau Pubblicità & Immagine - Printed in Italy - 04/08.
Comau S.p.A.
via Rivalta, 30
10095 Grugliasco - To (Italia)
Tel +39 011 0049111
www.comau.com