Up to 50 percent reduction in changeover times

IIn spring 2025, a development was put into operation in a new Audi press shop: The semi-autonomous tool changer from Genkinger GmbH for handling punching tools weighing 20 tons. It is the result of a development at eye level between the machine manufacturer and OEM.

The production processes in the press shop with new tools for special alloy steels for the manufacture of Audi e-car components were facing a transformation. The task was to develop a new intralogistics system based on a platform truck that would bring the new tools to the pressing stations efficiently, safely and precisely.

Instead of automating the entire changeover process, the company deliberately opted for a flexible solution that allows for human control - with defined transfer points, clear movement zones and an ergonomically optimized operating concept.

From vision to solution

In the beginning, the challenge was quickly formulated, but its implementation appeared very complex: tools for very special steel components for Audi's electric cars needed to be transported to the press and changed more quickly, safely and efficiently. Previous solutions, e.g. partly purely manually controlled processes or partly rail-bound change trolleys, were too inflexible and not safe enough for this new generation of machines and tools.

In close cooperation with Audi, Genkinger developed a customized, innovative solution. The changeover process begins with the delivery of the tools by truck and their unloading by overhead crane onto a mobile transport trolley. There they are positioned with millimeter precision. The die is then transferred to an electric multidirectional die change trolley, which first moves the die manually by radio remote control and then automatically places it in the press.

Process reliability thanks to redundant transponder tracks

The change trolley navigates the longer route semi-autonomously via a transponder track laid in the floor. This ensures that the tool change trolley takes exactly the right path. It is steered by the operator via radio remote control, with a selection function between several pressing stations. The redundant protection of all sensors, coupled with intelligent software and mechanical protection systems, ensures maximum work safety - an essential aspect for Audi. Particularly noteworthy: The intuitive operating logic, simple error prevention thanks to pre-programmed controls and ergonomic design make the system equally attractive for operating personnel and production managers. In addition, experience with the first completed press has shown that changeover times have been reduced by up to 50 percent. The other values for three further presses are available by the end of 2025 and, according to the projections, will reach a similar value.

Automatic push-pull mechanism

Comparing the transfer process with the new die changer with previous solutions, the progress is clear. While these still worked with purely manually controlled slides, the new system offers a synchronized push-pull mechanism in which the push and counter-push movements are automated and run simultaneously. This eliminates operating errors. The retrofitting of smart transponder systems and the flexible response to challenges in the hall layout also demonstrate this: As a machine manufacturer, Genkinger has not only implemented, but also thought along and advised. Decisive impulses such as the move away from inductive loops came about in intensive detailed discussions between Audi and Genkinger.

From project to platform

In the meantime, a solution has become a modularly expandable platform concept for further presses. The technology is even more scalable, and the next development step - a fully autonomous AGV die changer - is already being planned. Genkinger is convinced that this system will inspire the global automotive industry, including its many suppliers, to make tool changes faster and safer. The project presented here shows what mechanical engineering in Germany can look like today: as networked thinking between manufacturer and user, as a consistent further development of earlier solutions, and as a building block for the future of production in electromobility. "Genkinger was not awarded the contract by Audi with a finished product, but with an open ear, so to speak," summarizes Harald Harter, Key Account and Project Manager at Genkinger.

Award-winning innovation
Our semi-autonomous tool changer won the Best Award 2025.
👉 Here's the winner's report