Every tightening case has its own requirements. Security, surface protection, accessibility and much more. In our four business areas we have the optimal tool for all requirements.
The first covertec tools were already developed and delivered to customers by ekatec in 2005. In the meantime, the covertec system is available for almost all assembly tools. The aim in the development of covertec is to offer a complete system to prevent surfacedamage during the assembly process. With the covertec system, damage to the surface is significantly reduced, thereby reducing production costs. The risk of injury is significantly reduced when using covertec tools compared to standard assembly tools. In the meantime, complete assembly lines are equipped with covertec tools and it is the standard in the automotive industry.
The special properties of the covertec tools are achieved through the special covertec coating, which has emerged from many test series. This coating prevents surface damage to the vehicle, partially improves the attachment of the tools to the screwing case and increases the safety of machine-driven tools, since it envelops the rotating tool parts that are otherwise exposed, thus significantly reducing the risk of injury.
With the covertec product range, 100% of tightening cases can already be covered in many vehicle assemblies. If a suitable covertec tool is not available for a screwdriving application, the ekatec tool specialists can develop it according to customer requirements in the shortest possible time.
The product range in the covertec area includes the following product groups:
Damage during assembly is a cost factor that significantly affects cost-effectiveness. Avoiding assembly damage is therefore at the top of the list of economic factors for vehicle assembly. The rework necessary due to assembly damage (checking, polishing, painting, replacing, ...) ties up resources on the one hand and extends the average assembly times considerably on the other. However, especially in today's time with the greatest competitive pressure and small margins, reproducible profitability is an important requirement for survival on the market.
The covertec tools do not eliminate the human errors during assembly, which can lead to assembly damage, but prevent or reduce their effects. Be it when attaching the tool by giving it a guide through the covertec equipment, or in the event that the tool slips off or falls out of your hand. The covertec equipment protects the vehicle surfaces from damage by the tool
Injuries often occur, particularly when assembling vehicles, since the use of machine-driven tools often poses the risk that the assembly staff, with items of clothing, in particular gloves, get caught on the rotating tool parts and thus body parts could be entrained.
The resulting injuries often lead to longer absenteeism, which in turn represents a significant cost factor in assembly.
Thanks to the covertec equipment, many machine-driven tools can be made significantly safer. It envelops the rotating tool parts and thus effectively protects against injury.
With the covertec ISO + adapters from ekatec you can easily turn your covertec tools into electrically isolated tools. The TÜV-tested covertec ISO + adapter electrically separate the input and output. Voltages of up to 1,000 volts are thus reliably shielded.
The adapters are available in different versions for the ¼, 3/8 and ½ inch drives as well as for E 6.3.
For the output you can choose between ¼, 3/8, ½ inch, E6.3 and E11.
The adapters are compatible with the covertec tools from ekatec.
covertec ISO + adapter - the simple and inexpensive solution - electrically separated tools for every screw application.
Over 1,000 tightening operations by assembling a vehicle are not uncommon. Even more important is professional tool management to optimize processes.
This is exactly where firstmoves comes in and, on request, takes over the complete tooling of your assembly lines at a fixed price.
firstmoves ensures that all screwing cases are documented in time for the start of your new assembly line and that each screwing case has been assigned a tool that is optimally matched to the respective screwing case. Everything is documented in a database with information about suppliers. At the start of production, all tools for the tightening cases are optimally coordinated. You can start with the assembly.
With firstmoves, ekatec guarantees that all the tools, required for your assembly, are available at the start of production - at a fixed price.
The know-how of the ekatec tool experts ensures that the best solution for the respective tightening tool manufacturer can be selected independently from the catalog tools available worldwide and can be tried out on site.
This means that up to 98% of tightening cases can be equipped with catalog tools immediately. For the remaining assembly cases, ekatec also takes on the construction and provision of special tools as part of firstmoves. ekatec also has the relevant expertise here
firstmoves starts project planning. In this phase, the scope, duration and goals of the project are determined.
The customer, OEM or the general contractor of the planned assembly line presents his project and the schedule so that the planning of the firstmoves project can be set up accordingly. The goals for the firstmoves project are defined on the basis of analyzes of previous assembly processes.
Goals include: Reduction of the variety of tools, smaller tool storage, avoidance of paint damage, better ergonomics, more safety, faster assembly, less costs ...
A project plan is then drawn up by ekatec and adopted by the customer as a basis for the work
Bolting cases are identified and analyzed as early as the planning phase of the new assembly line, and tools and manufacturer preferences previously used are included.
Due to the long-term cooperation with almost all well-known automobile manufacturers and the resulting experience, ekatec can solve up to 98% of screwing cases with standard / catalog tools from its delivery program.
Particular strengths here are the product areas of flat drives and covertec (tools that prevent damage to the paintwork). Ekatec is the global market leader here.
As a specialist in special tool construction, ekatec has been a valued partner of many development departments of European automobile manufacturers for years. If special tools are required in the assembly process, ekatec offers optimal solutions.
In pre-series production, all screwing cases on the assembly line are recorded again under real conditions by the ekatec tool specialists, exactly described and tested.
Based on the results of the analysis phase, the ekatec employee brings along a tool selection that is already tailored to the individual screwdriving cases.
Together with those responsible for the assembly line and the fitters, it is checked whether the selection fits the respective screwing case optimally or whether readjustment is required.
With the help of the firstmoves test center, which provides a cross-section of the tool market with 1,200 tools, the most suitable tool is tested and determined on site at the assembly line.
Individual requests are taken into account, because not every tool that seems to be optimal in theory also meets the requirements of the mechanics in real work.
After all screwing cases on the assembly line have been recorded, described and tested, the construction of the firstmoves database begins at ekatec.
All screwing cases are entered with tool recommendations and supplier information for the tools. Each tightening case is clearly described in the database. The know-how of the ekatec tool specialists is also used here.
The possible tools are selected for each screwdriving application based on the framework conditions defined in the firstmoves project. Then the tools are coordinated with one another, for example with regard to tool life.
Paint protection and safety requirements influence the ranking of the possible tools for the individual screwing cases.
Taking all factors into account, the optimal tool is then determined for each individual screwdriving case. The same tools from different manufacturers are bundled into one manufacturer, taking into account any existing preferences - redundancies are thus avoided.
The tools are assigned to the individual screwdriving cases in the firstmoves database. Customer data, such as screwing lists, are checked and adopted on request.
All data relevant to tool procurement are stored in the database and alternative tools are shown. Finally, the database is finally completed.
At the same time, ekatec prepares the tools for the initial equipment of the assembly line
The database will be presented to future users in detail as part of a training course, either at ekatec GmbH or at the customer.
Then the firstmoves database goes into regular operation at the customer. There it is integrated into the logistics and procurement processes.
With their support, the user is always able to obtain the optimal tools for his new assembly line, regardless of the manufacturer.
Thanks to the clear connection of screwdriving case and tool, the optimal tool can be made available at any time with the help of this database, even when moving the assembly line or with the same screwing case in other projects.
According to the links in the firstmoves database, ekatec equips the assembly screwing cases with the tools.
This manufacturer-independent initial tooling ensures that production runs smoothly and on time.
The tools are delivered individually packaged. A final check is carried out at ekatec before shipping. A reliable logistics partner delivers the tools on the agreed date.
They are marked in such a way that they are optimally integrated into the logistics processes of the vehicle manufacturer and can also be assigned directly to the screwing cases in the assembly line.
On request, ekatec can accompany the assembly process for a defined period.
After the firstmoves database has been handed over and series production has started, the firstmoves project is usually complete. The course of the project is analyzed again as part of a final discussion. At this point, the first data on the development of costs and assembly times are already available, so that the success of the project can already be seen.
The increases in quality and other positive developments due to the firstmoves project can be measured and analyzed. After the firstmoves project has been completed, ekatec GmbH will of course continue to be available as a tool specialist and reliable supplier.
firstmoves - the process advantages
firstmoves - the economic advantages
The optimal solutions for your assembly tasks. Precisely solved with the high-quality assembly tools from ekatec. To ensure a smooth process.
Right from the start, we have focused on optimizing your assembly processes
Activity posed. Over the years, we have developed and built a wide range of assembly tools. Of course, challenges for our special tool construction came and come again and again. In the meantime, however, we have optimized many of our solutions so that we have them standardized in stock today.
At the same time, our tool experts keep an eye on the global tool market - because not every wheel has to be reinvented.
So today we can offer you the optimal tool for every screwdriving process in your assembly processes. Mostly from our own production, but from the globally available range if it makes sense.
Our product range in the field of assembly technology:
Our coordinated Hold & Drive unit is mounted on the Hold & Drive angle heads of the standard screw manufacturers. This consists of a counterholder, a changeable bit and a screwdriver socket. The unit is used, among other things, on tie rods, shock absorbers and side window screw connections. The Hold & Drive unit is characterized by reliability.
The adjustable slip clutch allows the torque to be limited to the counter holder (bit). This increases the service life of the bits massively and reduces malfunctions at the assembly station.
To avoid the imbalance that occurs when using extreme extensions, we recommend spindle-guided extensions. The unbalance when screwing is prevented by the bearing of the extension. Minimized wear and tighter screw tolerances are possible.
In order to produce the increasing variety of product variants with less manufacturing effort, we have developed combination sockets that accommodate two different wrench sizes. An otherwise necessary tool change is not necessary. The result is a reduction in production time.
ekatec-Torx socket with magnet holds your screw securely. Good handling and process reliability are guaranteed.
The standard bit holder with exchangeable bit guarantee long service life at minimal cost. All bit holders are also available in a covertec version that is surface-proof.
We have many lengths and sizes in our range.
If you cannot find anything suitable, please call us. We manufacture bits in the desired design for you.
The force-monitored pressure roller secures your adhesive connection; the roller can only be rotated when the pressure is applied sufficiently. The production of scooters up to 170N contact pressure, as well as pressure rollers for special requirements are possible.
In some screwing cases, the ekatec 110 ° angle head enables access to screwing points that cannot be reached with conventional tools. As an integrated module, our tongue gearheads can be mounted directly on these angle heads.
Tightening cases that are difficult to reach cannot always be avoided constructively. Tightening these with defined torques is the area of application for our flat drives.
Ekatec has been producing crowfoots (tongue gearheads) for many years. This is characterized by maximum service life and screwing accuracy. The use of our crowfoots enables cost-effective constructions. Very often, their use results in a reduction in production time. We support our customers in the development phase with installation space examinations in 3D. Short delivery times and good on-site support are a matter of course for us.
Our product range of crowfoots includes the following products
With different gear ratios and designs, our crowfoots ensure exact, constant torques. With wrench sizes from SW 7 to SW 26 and torques from 5.5 to 200 NM
With different gear ratios and designs, our crowfoots ensure exact, constant torques. With wrench sizes from SW 10 to SW 28 and torques from 20 to 60 NM
If you cannot find the right crwfoot in our range, we will be happy to manufacture it according to your requirements and will support you with 3D space analyzes during your design phase. For smooth, fast production.
