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Making Assembly Error-Proofing a Reality

Flexible just-in-time manufacturing principles, combined with growing product complexity, continue to increase demands on assembly operations. Sterner Automation is pleased to introduce the igentic® 531i, the first fully integrated error-proofing system designed for manual component assembly and box build requirements. The igentic® 531i provides the process intelligence, assembly logic and part verification needed to correctly guide your assemblers through individual steps, ensuring a consistent quality build each and every time.

The igentic® 531i Video

The igentic® 531i Efficiently Handles Multi-Faceted Assembly

  • Simple to retrieve transactional work instructions (TWI), featuring error-proofing logic, guarantee assembly steps are completed in sequence and correct torque values are applied
  • Encoder feedback from the precision positioning arm ensures that the location is correct before energizing the power screwdriver
  • Real time visual position feedback and a unique pictorial instruction format allow operators to follow each step efficiently
  • Screwdriver interface tooling allows for vertical or horizontal screw insertion
  • More complex build programs are easily accommodated with an optional rotary table, including table position verification and universal part locating tooling
  • Tool bit nests with sensor recognition and lighted indicators identify the correct bit for each process step
  • Pick-to-light identification system and pick sensors verify that the correct part is selected
  • Ergonomic table-top design with adjustable bin and tray modules provides flexibility for multiple applications
  • Simple to use trackball and opto switch ensure efficient operator navigation
  • User-friendly software utilizes colour-coded pictorial templates and teaching capabilities to help rapidly program new instruction sets
  • Part barcode scanning and operator identification provide product traceability
  • Multi-language compatibility meets global corporate requirements

The igentic® 531i Improves Quality and Customer Satisfaction

  • Ensures sequential and accurate assembly
  • Improves efficiencies by applying standardized assembly methodology
  • Minimizes expensive scrap and rework costs
  • Facilitates just-in-time and single piece builds
  • Reduces product changeover and assembler training time
  • Maximizes first pass yields and profitability

This intelligent assembly system can meet your production objectives now and in the future.

Sharpen your competitive edge by integrating Sterner Automation igentic® solutions into your production process today!



Mechanical Systems


·         Durable ESD-safe

·         Modular configuration

Bin Modules

·         Horizontal or vertical

·         Integrated pick sensors and LEDs

·         Configured for 3,6 or 9 standard bins

·         Maximum dimensions 75 mm (3”) high × 125 mm (5”) wide × 175 mm (7”) long

Tray Modules

·         Vertical

·         Integrated pick sensors and LEDs

·         Configured for 3 part trays

·         Maximum dimensions 50 mm (2”) high × 330 mm (13”) wide × 405 mm (16”) deep

Assembly Arm

·         Programmable to ± 3 mm (0.125”) of target centre

·         Integrates with standard power screwdrivers from most major suppliers


·         Supplied to hold and rotate the power screwdriver 90°

Precision Turntable

·         Adjustable tooling for part or board placement

·         360° rotation with 90° increments and position feedback

·         Maximum board size 375 mm (15”) × 550 mm (22”) long

Tool Changer

·         3-slot

·         Integrated sensor and pick light

·         12 mm (0.5”) maximum tool diameter


Electrical Systems

Electrical Cabinet

·         Integrated


·         19” monitor and trackball included as standard

Pick-to-Light Sensors

·         Retro-reflective with integrated LEDs


·         Opto switch advance

·         1D barcode scanner

·         Designed to CSA and OSHA safety standards


Software Systems

  • Windows XP
  • Software includes a built in process sequence editor with the following capability:
    • Import process sequences from PowerPoint presentations
    • Create and edit process sequences online or offline


Service Support

  • All equipment and software are programmed and tested prior to shipment
  • Electronic operator manual and instructions are included for reference
  • 24-7 emergency service hotline ensures maximum support


Interface requirements 

  • Power requirement – 100-240 VAC, 3 A, 50-60 Hz
  • Factory unlubricated dry air – 5.5 bar (80 psi)



  • 2D barcode scanners
  • Additional tool changer modules
  • Torque verification screwdriver systems to meet customer specifications
  • Automated fastener feed systems to meet customer specification
  • Foot pedal to replace opto switch advance
  • AutoCAD software integration module for preprogrammed position download
  • Stand alone quality control station with integrated vision inspection for label and component verification








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