The demand for disinfectants was high during the Corona pandemic. Metallatelier GmbH quickly produced a small series of a universal screwdriver for a chemical manufacturer for screwing caps of different container types. Part 1 of this user report reveals how the interaction of smart components from the drive to torque limiters and sensors to small shock absorbers in production leads to more speed in screwing, increased flexibility in bottle sizes and more safety.

Metallatelier GmbH occupies a special role in the field of special machine construction. This is due to the versatility demonstrated by the studio from Deggenhausen, Lake Constance County, its founder and owner David Fuchs and the workforce in various projects. founded in 1985 to provide technical support to artist friends whose design and architectural ideas David Fuchs helped to implement in the metal sector, the company continues to realize visions from art, architecture and design at a proven high technical level. In addition, David Fuchs and his team succeeded in 2006 in providing a manufacturer of cleaning agents with a utility model-protected special machine for previously unknown flexibility and fail-safety in the automated screwing of bottles. Thus the first universal screwdriver from Metallatelier GmbH was born.


Unique device for screw cap assembly

This first generation of the special machine is the basis for a successful contribution in the fight against SARS-CoV-2. The main protagonist is Bilgram Chemie GmbH, which trades in chemicals, among other things, but also produces washing and cleaning raw materials as well as cleaning agents. Those responsible at the company from Ostrach in Oberschwaben were familiar with the Universal Screwdriver 1.0, especially its singular screw cap assembly device, which automates the secure closure of a wide variety of cleaning agent bottles, including those with pump spray heads. So they asked Metallatelier to manufacture a follow-up series. While the first generation was about speeding up handling, the focus was now on increasing the production speed to meet the demand for disinfectants. "On the other hand, it was necessary to adapt our design even more variably and quickly to new closures and belt heights, because our customer wanted to fill primarily small vials with manual disinfection on three special machines," says David Fuchs, describing part of the new requirements.

To achieve these goals, the basic operating principle has remained the same as that of the previous design: The bottles are fixed in place by two clamping jaws covered with ethylene-propylene-diene (monomer) rubber (EPDM) centrally under the screwing mechanism. Four gripper rollers then grip the screw cap and screw it tight until the preset torque is reached. With the aid of the lower small shock absorbers, not only is the pneumatic slide braked, but the position of the dampers also determines the end position of the gripping mechanism, thus adjusting the machine to the different screw cap sizes. The carriage is also usually stopped by small shock absorbers before it reaches its end position. The upper one also serves to ensure that the carriage does not have to travel to its end position each time, but is stopped as soon as the gripper rollers are open far enough for the screwed unit to be conveyed further. Another time-saving application of the system: bottles with handles or pump spray heads can also be rotated for better onward transport or for the purpose of packing in containers or loading in an already sealed state and thus brought into uniform positions.