Redefining process safety

From left: Sebastian Forsthuber (Specialist in Material Separators, technosert) and Christian Schmidinger (Process Technology Manager, technosert)

Process reliability is a decisive competitive advantage in electronics manufacturing. The Austrian EMS service provider technosert, which has nearly 40 years of experience in electronics manufacturing, continues to pursue this path consistently. Under the leadership of Managing Director and Technical Director Jürgen Freynhofer, the company relies on the DIVISIO 5100 Gen 5 from the ASYS Group for component separation. The result: a highly automated, stable, and reproducible process that systematically ensures quality and sustainably supports technosert's high standards for precision and reliability.

Automation as the Key to Process Reliability

With the introduction of the component separation system DIVISIO 5100, technosert has taken a decisive step – away from manual influences towards a clearly defined, automated process. In the implemented island solution, the operator only handles loading and unloading, while all other steps run fully automatically.

This structure reduces variability in the process and creates consistent results. "The system eliminates the natural variability of manual activities in the process – and that makes all the difference," explains Christian Schmidinger, Process Technology Manager at technosert.

DIVISIO 5100: Precision, Speed, and Control

The core of the solution is the DIVISIO 5100 – a state-of-the-art component separation system specifically designed for maximum process safety and efficiency.

The machine operates autonomously and under continuous self-monitoring, checks tools before production start, and optimizes processes in real-time – key factors for stable manufacturing workflows.

Key features include:

– Highest precision and dynamics through linear motors and positioning accuracy up to ±10 μm
– Fast cycle times of 2–2.5 seconds thanks to double-spindle and double-gripper technology
– Automatic tool changes and integrated camera and measurement systems to ensure consistent cut quality
– 100% cut control and adaptive process management that detects and corrects deviations
– Gentle handling through force-controlled grippers and soft-stop function to reduce mechanical stress
– High autonomy times of up to 20.5 shifts thanks to integrated tool management
– Open interfaces (OPC UA, IPC-Hermes, IPC-CFX) for seamless integration into networked production environments

Thus, the system combines key requirements of modern SMT manufacturing: precision, flexibility, and digital connectivity.

Robust Processes for Increasing Demands

The new solution particularly demonstrates its strength with complex or large-format assemblies. Precise milling and sawing enable low-stress processing and prevent damage to sensitive circuit boards.

Continuous data collection and self-monitoring ensure that process deviations are detected early. This not only achieves quality but also maintains it permanently – a crucial factor for industries with high standards such as medical technology, aerospace, or ATEX applications.

Holistic Approach Instead of Individual Measures

The implementation of DIVISIO is part of a comprehensive concept. Together with the ASYS Group, a scalable, modular manufacturing solution has been created that already considers future requirements. Thanks to its modular design, numerous configuration options, and easy retrofitting, the system can be flexibly adapted to new products, batch sizes, or automation levels.

Partnership as a Success Factor

The successful implementation is based on a long-standing collaboration: since 2005, technosert and the ASYS Group have maintained a close partnership.

The added value of this cooperation was also evident during the introduction of the new system: challenges during the project were jointly and solution-orientedly overcome.

“What matters is not that everything is perfect from the start – but that solutions are found together,” says Schmidinger.

More Than Efficiency: Sustainable Improvement in Daily Operations

In addition to increased process reliability, daily workflows also benefit:

– Clearly structured processes
– Better planning
– Targeted deployment of skilled personnel

This allows know-how to be increasingly used for monitoring and optimizing activities – an important step towards future-proof production.

Outlook: Scalable Manufacturing with Perspective

For technosert, the new component separation solution is not an endpoint but the basis for further developments – for example, in automation, traceability, or data-driven process optimization.

The DIVISIO 5100 exemplifies how modern manufacturing technology and collaborative partnerships can work together to create sustainable process reliability.

Conclusion

“It was crucial for us to find a solution that not only works today but also supports us in the future. With the achieved process reliability and automation, we have accomplished exactly that – together with a partner who shares this journey.” (Jürgen Freynhofer, Managing Director and Technical Director, technosert electronic GmbH)