Modular, flexible, future-proof: the Rejlek Multi Line

Automation technology is constantly evolving – and with it, the demands placed on modern production facilities. In order to respond flexibly and efficiently to customer requirements, we at Rejlek rely on a new, forward-looking solution: the Rejlek Multi Line. This specialised automation system combines maximum precision with modularity and impressively demonstrates how today’s production systems can adapt to changing market requirements. We have summarised all the information for you in this blog.

The challenge: combining flexibility and precision

In industrial manufacturing, companies are increasingly faced with the challenge of responding flexibly to individual customer requirements while ensuring the highest quality and efficiency. Turnkey systems, which are often designed for the production of a single product, offer only limited customisation options. The solution? A modular concept that enables both production diversity and economic scalability.

The solution: a modular special-purpose machine

With the Rejlek Multi Line, we have developed our own state-of-the-art production facility in-house. It is based on a modular design that allows us to manufacture different products for different end customers. This gives Rejlek a new level of adaptability and ensures greater independence from external machine manufacturers.

Typical examples of applications for this concept include:

– Modern sensor technology products (e.g. rain sensors, radar sensors)

– Multi-pole plugs with overmoulded stamped contacts

– Overmoulded stamped grids

– Other hybrid components that combine stamping, injection moulding and testing processes

A central element of the system are two Stäubli TS2-100 Scara robots, which contribute significantly to the smooth operation with their precise and fast handling. These robots are responsible for inserting stamped parts (Elopins) and bushings precisely into the injection mould so that overmoulding can then take place. The second robot removes the finished parts and transfers them to an inspection and final cleaning cell.

Why modularity is crucial

The modular design of this solution offers numerous advantages:

• Flexibility: The production plant can be quickly converted for different products without requiring major modifications.
• Cost efficiency: Production processes can be optimised thanks to an adaptable machine configuration, thereby minimising downtime.
• Future-proof: New requirements or product changes can be easily integrated without the need for a completely new machine.
• Competitive advantage: Rejlek can respond more flexibly to market trends and offer its customers customised solutions.
• Purity requirements: A key feature of the Rejlek Multi Line is the downstream, encapsulated testing and cleaning unit with integrated packaging. This allows very high purity requirements (similar to ISO 8) to be met without having to design the entire production environment accordingly – a clear cost advantage for our customers.

The role of Scara robots

Special attention is paid to the Stäubli TS2-100 Scara robots, which are known for their exceptional precision and speed. With a payload capacity of up to 8.4 kg and a reach of 1,000 mm, they enable the shortest cycle times and maximum repeatability. Thanks to their innovative design with IP65 protection class and hygienic options, they are also suitable for a wide range of production environments.

Use case from our series production: 28-pin connector assembly

One successfully completed project clearly demonstrates the capabilities of the Rejlek Multi Line: a 28-pin connector assembly with sockets. In a cycle time of just 24 seconds, a double injection moulding tool separates and overmoulds 8 rows of Elopins (stamped contacts) and 4 sockets. This is followed by automated transfer to the test cell, including cleaning and various tests (e.g. camera and electrical tests). Finally, the parts are placed in trays fully automatically. A convincing combination of state-of-the-art technology.

Partnership as a factor for success

A key factor in the success of the new Rejlek Multi Line is the long-standing partnership between Rejlek and Stäubli. The close cooperation between our two companies has made it possible to develop a tailor-made automation solution that not only offers maximum precision but also enables cost-effective production.

Conclusion: A glimpse into the future

The introduction of the Rejlek Multi Line impressively demonstrates how sophisticated automation technology and modular concepts can revolutionise industrial manufacturing. The combination of precision, flexibility and efficiency makes this system a pioneering solution for modern production.

With innovations like these, we at Rejlek are setting standards in the industry – and proving once again that automation not only increases efficiency, but also creates new opportunities for customised manufacturing.

Would you like to find out more? Then get in touch with us right away – we look forward to hearing from you.