Precision that stays on beat

The modular design of IEF-Werner's components allows Pematech to reuse pre-assembled modules for similar applications. This saves costs and simplifies the design. (Image: IEF-Werner GmbH)

Positioning systems with linear units – such as the spindle axes of the profiLINE series – have been used by Pematech for many years. Robustness, precision, and reliability also convince the end customers. (Image: Pematech GmbH)

Thomas Hettich – here giving a lecture during the Innovation Days at IEF-Werner in November 2025 – is responsible for the product area of linear axes and motorized rotary tables. (Image: IEF-Werner GmbH)

Thomas Ketterer from Pematech GmbH reports on the use of IEF-Werner's linear technology in testing and assembly lines. (Image: Pematech GmbH)

When automated testing and assembly processes are to run economically and safely, the interplay between system design and linear technology is crucial. The special machine builder Pematech has relied for years on components from IEF-Werner. Experiences from numerous projects show: precise linear technology combined with deep expertise significantly contributes to short cycle times and low manufacturing costs.

"We design and manufacture complete assembly lines for our customers as needed, for example for circuit boards, electronic assemblies, and devices," describes Thomas Ketterer, Key Account Manager at Pematech. The special machine builder from Radolfzell on Lake Constance is part of Swiss-based Asic Robotics AG with around 80 employees. Pematech's portfolio includes automated test lines for various quality assurance tests, linear transfer and rotary turntables, robot cells, custom solutions for assembly, as well as modular software programs for control, process optimization, and product traceability. Renowned companies worldwide rely on their deep expertise in planning, design, manufacturing, and assembly of turnkey test and assembly lines, as well as demand-driven testing technology. Ketterer states: "We tailor the systems precisely to our customers' individual processes. This enables them to meet often demanding requirements regarding functionality, performance, efficiency, and quality." Customers mainly come from Europe, Asia, the USA, and Mexico. Pematech also supports users with comprehensive service.

Every tenth of a second counts

"Many of our customers are from the automotive industry, an important but highly competitive market," reports Ketterer. This is complemented by medical technology, smart home, consumer and industrial goods, and the electrical industry. Often, these are cycle-critical processes where every tenth of a second counts. This is especially true for automotive customers, for example when mounting electrical assemblies and components such as circuit boards. "The processes at the users' end must be perfectly coordinated," says Ketterer. "There must be no delays between individual steps." Therefore, linear technology plays a decisive role in handling. For years, the special machine builder from Radolfzell has relied among others on its partner IEF-Werner from Furtwangen.

"Screwing, dispensing, cleaning, laser marking, resistance welding, end-of-line testing, and plasma treatment – for one automotive customer, we designed a line that covers all process steps," he describes. This includes the fully automatic joining of a flexible circuit board with a connector, as well as external processes such as applying thermal paste. The system operates camera-assisted with position correction and tolerance compensation. It is particularly suitable for three-dimensional, space-saving electronic assemblies. Additionally, the line is connected to a higher-level Manufacturing Execution System (MES), with a line management system – the Pematech LineManager – aggregating data from all stations centrally and serving as an interface to the MES.

This allows production and status data to be collected in real-time, transparency to be created, and continuous traceability to be ensured. Pematech has integrated the individual processes as an integrator and general contractor into a cohesive whole. The result: a customized, reliable, and fast line.

Challenge: 360-degree inspection

"We supplied individual axes for tasks ranging from screw connections to portal systems," describes Thomas Hettich, who supports Pematech. He is Product Area Manager for linear axes and motorized rotary tables at IEF-Werner. "In total, there are nearly 45 linear axes in the entire line." Hettich cites a special task in the designed assembly line as an example: "The products must be removed from the workpiece carrier and inspected from multiple angles with camera systems. The process must not be interrupted." A maximum of two and a half seconds was available for this operation to ensure the cycle time at the end of the line.

Together with Pematech, the IEF team developed a positioning system specifically for this workstation. It is based on IEF standard timing belt axes from the Modular series. The Z-axis of type Modular 68 was supplemented with an additional rotary unit. In total, this axis must move a mass of seven kilograms. The compact linear unit Modular 68 is especially suitable as a vertical axis and impresses with high repeat accuracy of ±0.04 millimeters at speeds up to two meters per second. "This combination of precision, dynamics, and durability makes this linear unit an ideal solution for automated testing and assembly processes," says Thomas Hettich. "Thanks to the modular design of the axes and the precise configuration, we could synchronize the movements exactly with the cycle time."

The Modular 68 has proven its worth in use many times: not only can cycle times be reliably maintained, but costs remain low, and adjustments to specific process requirements are easily possible. "The kinematics allow the motor to stay stationary while the carriage on the Y-axis is fixed, and only the base moves up and down," explains IEF expert Hettich. "We can optimize space and ensure free travel paths."

During the quotation phase, IEF-Werner provided CAD data and detailed calculations. Both sides could thus be confident that the system could later be used as planned, without unexpected changes or cost increases. Ketterer states: "We can directly integrate the finished CAD drawings, and the delivery is arranged so that the axis arrives ready for assembly on the pallet. This greatly simplifies our work and gives us enormous security."

Reusable assemblies

A central goal in developing special machines is to be able to reuse individual assemblies. This means Pematech does not have to completely redesign each system. "For example, if we use a portal system, we can simply adapt, shorten, or extend it for new projects without reinventing the wheel," explains Ketterer. This approach simplifies design, saves development time, and makes machines more efficient and cost-effective to produce.

Close partnership for stable production processes

Collaboration with IEF-Werner convinces Pematech through solid technical expertise, practical advice, and precise coordination with the system cycle times. In a specific case, initially variants with two handling units were considered. This solution would have been technically feasible but economically unattractive. Therefore, the decision was made in favor of a clever, constructively and control-technology optimized solution from IEF-Werner, using only one unit that offers the same benefits – making the system more cost-efficient and thus more competitive.

The robust linear systems operate almost maintenance-free and ensure high availability. This is fundamentally important, especially for international customers, where a service technician may not be immediately available abroad.

"What I particularly appreciate about IEF-Werner is not only the quality of the axes but the entire package – from design to practical implementation," explains Thomas Ketterer. "With each system, we receive valuable tips on cable routing or axis setup, allowing us to plan handling, force, and speed optimally. Critical factors such as electrostatic charging near sensitive products are also considered together. This saves time, reduces the need for handling units, and gives us a clear cost advantage."