Flywheel production at ZF, Bratislava

For the gear manufacturer ZF, we have programmed and placed into service a plant in Bratislava (Slovakia) for the assembly of the dual mass flywheel (DMF) qogttvx. A particular challenge here were the two KUKA JET robots on a carriage for transporting parts to the individual processing stations.

Technical Details


Assembly of the dual mass flywheel for ZF in Bratislava (Slovakia)


  • Station for inserting rivets in the flywheel with a KUKA robot scara KRC5
  • Sprocket assembly: The sprockets are supplied from a storage, inductively heated and shrunk onto the flywheel with an electro-mechanical press
  • Subsequent testing station controls the axial and radial position of the sprocket using a camera
  • Balancing station
  • The grease station fills the DMF with grease, the cover is applied and pressed in electro-mechanically
  • Finally, the fully assembled and tested work pieces are preserved and made available on an delivery conveyor to the worker for packaging


  • 5x S7-300 with OP77B and POSMO drives to control individual stations
  • 1x S7-300 with MP277 as head control for security functions and order control
  • 1x KUKA KRC5 scara
  • 2x KUKA KR60 Jet


  • Cameras for position control
  • Data acquisition MDE / PDA
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