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Successful project implementation thanks to components from Zimmer Group
November 3, 2025
The automation of solar system production is becoming increasingly important, not only to increase production output, but also to ensure consistently high quality standards. This also applies to the manufacture of fasteners for solar modules. In the plant recently completed by machine and plant manufacturer TEAM Automation Berlin in close cooperation with Zimmer Group, these can now be manufactured automatically and in a controlled manner for the first time.
Challenges and innovative solutions
TEAM Automation Berlin implemented a fully automated assembly system for a customer in the solar industry. A key challenge was the precise and controlled handling of aluminum brackets and small parts while adhering to the tightest dimensional tolerances. Together with Zimmer Group, a highly automated solution was developed in which several gripper models and a quick-change system from the Rheinau-based component manufacturer are in continuous use.
The challenges were exacerbated by the current economic situation: a weak economy and a certain reluctance to invest on the part of customers prompted TEAM Automation Berlin to rely on components from Zimmer Group, which are characterized by maximum reliability and precision, excellent performance, and a long service life.
Grippers as key success factors
Within the system, the GEP2000 series electric small parts gripper and the MGP800 series pneumatic end effector perform key tasks in workpiece feeding, assembly, and packaging. As soon as they are fed into the system, aluminum angles are not only gripped by the GEP2000, but also measured at the same time – a novel solution in this form. The accuracy of the integrated Hall sensor technology in combination with the flexible IO-Link interface in the gripper makes this possible and demonstrates the gripper's performance capabilities. This dual functionality simplifies process steps within the system and saves valuable time in the overall process.
In the next step, the Zimmer Group MGP800 series gripper picks up the pre-checked components and transfers them to the linear conveyor. MGP800 grippers are also used for the assembly of the clamps, which is controlled by a Zimmer Group quick-change system (HWR2000 series) with vacuum grippers and robots. These guide the components precisely to the assembly station, where they are combined with screws, O-rings, and toothed washers and attached to the aluminum bracket. Finally, the robot uses the Zimmer Group grippers to place the finished products in shipping cartons, which are transported away on a conveyor belt system.
Future-proof automation through smart component selection
For TEAM Automation Berlin, Zimmer Group's extensive product portfolio and in-depth expertise were decisive factors, as were its integration capabilities and service quality. The rapid integration of the components, technical advice on special solutions, and the durability of the grippers led to an efficient and future-proof implementation of the system concept.
With components from Zimmer Group, TEAM Automation Berlin was able to implement an economically viable and technically innovative solution for the production of fasteners for solar cells. The system meets the highest standards of precision and reliability, supporting the customer in future-proof, automated production.
A look at this project shows that a smart choice pays off – both in terms of process reliability and investment protection. Those who do not rely solely on standard solutions when selecting components, but keep the entire process chain in mind, create the basis for scalable and low-maintenance automation.
For more information on Sustainable automation for mounting solar modules talk to Zimmer Group UK Ltd