Semi-autonomous tool changer for presses

In spring 2025, a new development went into operation at a new Audi press shop: the semi-autonomous tool changer from Genkinger GmbH for handling 20-ton stamping tools. It is the result of development on equal terms between the machine manufacturer and the OEM.

Production processes in the press shop, featuring new tools for special alloy steels used to manufacture Audi e-car components, were facing a transformation. The task was to develop a new intralogistics system based on a platform trolley that brings the new tools to the press stations efficiently, safely, and precisely.

Instead of automating the entire changeover process, a flexible solution was deliberately chosen that allows for human control – with defined transfer points, clear movement zones, and an ergonomically optimized operating concept.

Award-winning innovation
Our semi-autonomous tool changer was recognized at the 2025 Best Award.

From vision to solution

At the beginning, the challenge was quickly formulated but appeared very complex in its implementation: tools for very special steel components for Audi’s e-cars were to be transported to the press and changed faster, more safely, and more efficiently. Previous solutions, e.g., partly purely manually controlled processes or partly rail-bound change trolleys, were too inflexible and not safe enough for this new generation of machines and tools.

In close cooperation with Audi, Genkinger developed a customized, innovative solution. The changeover process begins with the delivery of the tools by truck and their unloading by overhead crane onto a mobile transport trolley. There, they are positioned with millimeter precision. The tool is then transferred to an electric multi-directional tool change trolley, which initially moves the tool manually via radio remote control and then automatically inserts it into the press.

Process reliability through redundant transponder tracks

Navigation of the change trolley over the longer travel distance is semi-autonomous via a transponder track laid in the floor. This ensures that the tool change trolley takes exactly the right path. It is steered by the operator via radio remote control, with a selection function between several press stations. The redundant protection of all sensors, paired with intelligent software and mechanical protection systems, ensures a maximum level of occupational safety – an essential aspect for Audi. Particularly noteworthy: the intuitive operating logic, simple error prevention through pre-programmed control, and the ergonomic design make the system equally attractive for operating personnel and production managers. Furthermore, based on experience at the first completed press, changeover downtime could be reduced by up to 50 percent. Further values for three additional presses will be available by the end of 2025 and are expected to reach a similar level according to projections.

Automatic push-pull mechanism

Comparing the transfer process of the new tool changer with previous solutions clearly shows the progress. While those still worked with purely manually controlled slides, the new system offers a synchronized push-pull mechanism in which the push and counter-push movements take place automatically and simultaneously. Operating errors are thus excluded. The retrofitting of smart transponder systems and the flexible response to challenges in the hall layout also show: as a machine manufacturer, Genkinger did not just implement, but thought along and advised. Decisive impulses, such as the move away from inductive loops, came about in intensive detailed discussions between Audi and Genkinger.

From project to platform

In the meantime, a solution has become a modularly expandable platform concept for further presses. The technology is even further scalable, and the next development step – a fully autonomous AGV tool changer – is already in the planning stage. Genkinger is convinced: this system will inspire the global automotive industry, including its many suppliers, to make tool changes faster and safer. The project presented here shows what mechanical engineering in Germany can look like today: as networked thinking between manufacturer and user, as a consistent further development of previous solutions, and as a building block for the future of production in electromobility. “Genkinger was not awarded the contract by Audi with a finished product, but so to speak with an open ear,” summarizes Harald Harter, Key Account and Project Manager at Genkinger.