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Brakes speak Italian in Milwaukee: a full system with ABS every 2.5 minutes

Automac COP PericoAssembly line producing brakes for the legendary Harley Davidson and testing systems for Brembo brake kits for Harley Davidson achieved thanks to the oh- so-Italian-genius of AUTOMAC. Another outstanding success for the company, making us even more competitive on the world market.

Few motorcycles have reached legendary status and even fewer brands have created a lifestyle that is wild and free....much less at the weekend.
Harley Davidson is the brand, the legend, the lifestyle and the dream.
A mechanical instrument concealing a strong commitment to research and development in new technologies behind the guise of immobility and tradition.
For motorcycles, this road leads to an intelligent use of electronics and precision mechanics that will last a long time.
Several subsystems are involved and one of the most important is the brake system.
This is because it is often the last resource the rider has available to prevent a collision. But even when there is no imminent danger, an efficient and effective brake system ensures a pleasant and satisfying ride. This result is achieved through several factors, some internal and some external.

Automac004 Linea completaAutomac's experience in brake assembly systems, particularly with the solutions delivered to Brembo – says Franco Perico, Automac's driving force and energy – close collaboration with suppliers and our desire to compete have led us to study and create an innovative assembly line solution to strict UL standards, to enable production efficiency, safety and quality in the assembly and testing of the brake systems installed on all models of the legendary Harley Davidson".

During the development of Automac assembly and testing lines, the focus is on maximum flexibility: every line is capable of processing four types of brake system and requires no mechanical set-up, only the insertion of the product code into the assembly line computer.
"We can process – says Perico – complete front/rear systems with or without ABS as well as individual front/rear systems. The computer supervising the line has a multifunctional software which handles all production data and recovers any waste by type. Each system consists of a main line along which the shuttles run with supports to transfer the components to the various workstations. The shuttles also have an RFID memory where all assembly information and testing values are stored".
Each line consists of two semi-automatic stations with an operator and two automatic stations.
The semi-automatic stations each have one operator who, using the relevant servo-mechanisms, assembles the brake system. All the brake system's coupling connections are attached by screwing units with angle/torque control and supported by reaction arms with counter-reactions.

The first of the automatic stations on the line, provided by AMC-Vacuum Solution ( and built-in system Automac performing the leak test in depression, bleeding, and its coverage of plant with the correct amount of brake fluid suitably degassed. Each of the above operations will also be displayed on a touch screen monitor placed near the unit in such a way as to enable the operator to check the correctness of the process.
The second automatic station is the most innovative and important on the system - says Perico - designed by Automac cooperation with Festo (, which provided the servo motors and their drives and collaboration of AMC-Vacuum Solution for the management of ABS control unit allows complete testing of all systems assembled.

On the line, the brake levers connected to the front and rear pump are enabled by actuators with recirculating ball bearing rails controlled by servomotors. Load cells are inserted into the driving heads to measure the force in relation to movement directly on the lever.

After assembly and testing, the shuttle transfers the brake system to the first workstation where the operator unloads it and deposits in thermoformed packaging.
An assembly line for a system with ABS has a cycle time of 2.5 minutes.

"Automac has been able to build these lines - concludes Perico - thanks also to the synergies share with the Cosberg group of which Automac is part. These synergies have allowed us to meet customer's specifications and agreed delivery times".

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