Tool Changer Up to 50 Percent Reduced Changeover Times

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Genkinger GmbH

FAULHABER Drive Systems

Taiwan Machine Tool & Accessory Builders' Association (TMBA)

SIMTOS (Seoul International Machine Tool Show)

In spring 2025, a new development was launched in an Audi press shop: the semi-autonomous tool changer by Genkinger GmbH for handling 20-ton stamping tools. It is the result of an equal partnership development between the machine builder and the OEM.

The production processes in the press shop with new tools for special alloyed steels for the manufacturing of Audi e-car components were on the brink of transformation. The task was to develop a new intralogistics system based on a platform truck that could transport the new tools efficiently, safely, and precisely to the press stations.

Instead of fully automating the entire changeover process, a deliberate choice was made for a flexible solution that allows human control – with defined transfer points, clear movement zones, and an ergonomically optimized operating concept.

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From Vision to Solution

At the outset, the challenge was quickly defined but seemed very complex to implement: tools for very specific steel components of Audi's electric cars needed to be transported to the press and exchanged faster, safer, and more efficiently. Previous solutions, such as partially manually controlled processes or partially rail-bound transfer carts, were too inflexible and not safe enough for this new generation of machines and tools.

In close collaboration with Audi, Genkinger developed a customized, innovative solution. The exchange process starts with the delivery of the tools by truck and their unloading via overhead crane onto a mobile transport cart, where they are positioned with millimeter precision. The tool is then transferred to an electric multi-directional tool-changing cart, which is initially operated manually via remote control and then automatically inserts the tool into the press.

Process Reliability Through Redundant Transponder Tracks

The navigation of the transfer cart over the longer route is semi-autonomous via a transponder track embedded in the floor, ensuring that the tool-changing cart follows the correct path precisely. Steering is conducted by the operator via remote control, with a selection function for multiple press stations. The redundant safeguarding of all sensors, combined with intelligent software and mechanical protection systems, ensures a maximum level of work safety—a key aspect for Audi. Particularly noteworthy are the intuitive operating logic, the simple error prevention through pre-programmed controls, and the ergonomic design, making the system equally appealing to operators and production managers. Furthermore, changeover times at the first completed press have been reduced by up to 50 percent, according to experience. Data for three additional presses will be available by the end of 2025 and, based on projections, are expected to achieve similar results.

Automatic Push-Pull Mechanism

Comparing the transfer process of the new tool changer with previous solutions highlights the progress made. While manual sled systems were still used previously, the new system features a synchronized push-pull mechanism where the push and counter-push movements are automated and occur simultaneously. This eliminates operating errors. The retrofitting of smart transponder systems and the flexible response to challenges in the hall layout also demonstrate that Genkinger, as a machine manufacturer, not only implemented but also thoughtfully advised and innovated. Key improvements, such as moving away from inductive loops, emerged from intensive detailed discussions between Audi and Genkinger.

From Project to Platform

In the meantime, the solution has evolved into a modularly expandable platform concept for additional presses. The technology remains further scalable, with the next development step—a fully autonomous AGV tool changer—already in planning. Genkinger is confident that this system will inspire the global automotive industry, including its many suppliers, to make tool changes faster and safer. The project presented here demonstrates what mechanical engineering in Germany can look like today: as interconnected thinking between manufacturer and user, as a consistent advancement of previous solutions, and as a building block for the future of production in electromobility. "Genkinger won the contract from Audi not with a finished product, but, so to speak, with an open ear," summarizes Harald Harter, Key Account Manager and Project Leader at Genkinger.

*Freelance author