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Assembly Expertise

A battery cooling module, a high-pressure petrol pipeline or a complex heat sink for urea direct injection – these are just three of the many examples of assemblies from Hörnlein. As with individual parts, assemblies are also manufactured entirely in-house. Our degree of automation in assembly, connection and joining technologies is unusually high.  The Hörnlein smart factory is an integrated, flowing, communicating and self-learning system in all of its components. Value-stream-optimised: Time, flow and pull in the evolution stage Industry 4.0.

Assembly

Assembly processes are automated to the greatest extent at Hörnlein. The assembly lines are configured for the customer and the customer's product in out internal mechanical engineering.  250,000 individual parts are assembled into assemblies on assembly lines in this way at the Šahy location, for example. Even under clean room conditions, if necessary.

Brazing

Brazing is one of the typical joining technologies in assembly manufacturing. Hard brazing is used at Hörnlein. Non-alloyed, alloyed and stainless steel are processed using nickel-based and copper solder. Continuous furnaces with conveyor belts are integrated into the assembly lines for this.

Welding

Welding is one of the typical joining technologies in assembly manufacturing. Depending on the optimal area of application, laser welding, MIG and TIG welding and resistance welding are used Hörnlein. Non-alloyed, alloyed and stainless steel as well as aluminium are processed. Hörnlein possesses special laser welding know-how – particularly with aluminium.

Quality Testing

At Hörnlein, quality is created, not achieved through testing. Making zero defects, allowing zero defects and passing on zero defects. "Measure it or forget it" is the motto because there is a wide variety of information documented in the manufacturing processes themselves during manufacturing. In most cases defects can be avoided before they occur by using the data.

Tightness, flow or
residual dirt:

Various helium leak testing methods, pressure differential methods, residual dirt analysis

Metallurgical inspections, stability of welded and soldered connections:

Various destructive testing methods, microsections

Surface quality:

Tactile testing

Size and geometric accuracy: 

Tactile testing and visual inspection