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Automation in the automotive world has always been the core business of Sir, which throughout its history has designed and built robotic lines and cells capable of covering the entire production chain of typical components for a modern car.
The industry-specific requirements imposed by the automotive sector in terms of quality repeatability, now comparable to those required in the aeronautics industry,
with extremely short cycle times and near 100% efficiency, make automotive the most demanding testing ground for modern robotics.
In this context, Sir has developed comprehensive solutions characterized by a high level of integration.
These solutions range from processing raw cast components and cores to handling them during the loading and unloading of machine tools, from finishing processes after the initial machining to final assembly operations and palletization.


The SIR assembly lines in the automotive sector mainly concern the assembly of engine heads, wheel groups, engine distribution groups or turbines. In addition to this SIR has developed solutions for the welding and assembly of car and motorbike frames.
Generally this lines are capable of self-tooling for each different product code.
The robots are assisted by other accessory systems designed and produced by SIR such as Cartesian manipulators, presses, etc.

Functional Integration

We build robots and mechanisms that interact to share information and balance the workload, to assemble any type of product.

Quality and Efficiency

SIR assembly solutions deliver drastic reductions in production times with impressive increases inquality. All with efficiency over 90%.


SIR lines’ automatic retooling opens the way to randomized production and automation which leaves behind the rigidities of the past in progression to the one-piece batch.

Functional Characteristics

  • Randomized production and automatic retooling
  • Production traceability
  • Optical inspection and functional testing of the finished product

Automotive Chassis Assembly

Assembly operations and welding operations on car and motorcycle chassis.
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Cilinder Heads Assembly

Interference fitting of seat and guide valve units in high-performance engines, using dedicated robots and presses.
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Electromechanical cooling units assembly

Assembly of fan unit and cooling unit for truck radiators.
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Engine Turbo Unit Assembly

Preparation and assembly of manifolds and bushings in turbo units
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Roller Assembly

Complete assembly of the roller unit for earth-moving machinery.
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Wheel Unit Assembly

Fitting of bushings of stab axles of the control arms as well as complete assembly of wheel units.
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Raw material processing made with robots entails the use of different working configurations: the first one involves components on board of the robots and tools positioned statically or generally outside of the robot itself. In this scenario, SIR has developed a patented solution known as “”Modulo.””
This solution entails the tools being positioned on a rotating station controlled by the robot, with two different typesetting for aluminum or cast iron applications
This approach is aimed at optimizing the efficiency and quality of the machining paths.
The second configuration elements involves in fixed position, with tools mounted directly on the robot.
Both of these configurations offer significant flexibility and allow SIR to tailor the ideal solution to meet the specific needs of its customers, while simultaneously ensuring high-performance outcomes and enhanced efficiency in the machining processes.

Repeatable Quality

Thanks to adaptive tool compensation and virtual programming techniques, SIR robots guarantee constant and repeatable finished quality, compensating for variations between the actual piece and the nominal model.

Modular Solutions

The patented toolholder module, able to house grinding wheels, discs, milling cutters, belt-polishers, supported by automatic tools changing system and magazine, makes the solution completely flexible and able to produce small batches.

Safety and Environment

With scraps collection and dust extraction system, SIR cells are fully compliant with occupational health and safety legislation.

Functional Characteristics

  • Multifunction tool module
  • Adaptive tool compensation
  • Virtual Programming

Battery Tray Deburring

Cutting and deburring operations of aluminum battery tray cases by using modular solutions.
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Brake Callipers Cutting and Deburring

In the manufacturing process of aluminum brake calipers, cutting and deburring operations are carried out with great precision using modular solutions that include a wide range of specialized tools. These tools include highly efficient cutting disks, sharp blades, sophisticated spindles, and advanced pneumatic systems. What sets these tools apart is the presence of passive compensation…
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Giga Casting Trim and Deburring

Robotic operation of cutting the sprues by using plasma flashlights.
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Motor Block and Head Deburring

Cutting and deburring operations of aluminum engine heads and crankcases using modular solutions.
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Structural part and subframe trim and deburring

Loading/unloading of blanking and/or sprue-removal units and subsequent deburring by anthropomorphic robots.
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SIR’s robotic solutions represent a significant evolution in industrial automation, enabling the execution of complex processes in a fully automated manner. SIR’s achievements extend beyond the typical applications of robotics, encompassing robotic lines where loading and unloading activities synergistically integrate with the production processes and assembly. Furthermore, SIR redefines the concept of machine tool tending by creating multifunctional lines that adeptly combine the traditional approach with a wide range of secondary procedures.

High Production Rates

SIR manipulation systems guarantee speed and efficiency: equipped with the best industrial or collaborative robots on the market, they have specific grippers and mechanical systems, with solutions ranging from the single unit to sequential tending lines.

Universal Feeding

2D and 3D artificial vision with binpicking capability allows the use of universal feeding systems, requiring no retooling between batches, with impressive simplification of industrial logistics.

Quality Control

Using the robot as optic sensor positioner, manipulation lines can be equipped with inspection systems that can objectively assess processed product quality through surface, dimensional or assembly checks.

Functional Characteristics

  • Feeding guided by vision systems
  • Dedicated grippers
  • Functional integration
  • Automatic product inspection

Bin picking

Bin picking of items placed inside bins using 3D vision systems in fixed position, on controlled axes or on board robots.
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CNC and Machine Tool Tending

CNC and machine tool tending by anthropomorphic robots through the realization of robotic lines.
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Part Inspection (2D and 3D)

Use of robots and cobots for complex two- or three-dimensional inspection of machined or assembled items.
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The ability to shape and define the form of a semi-finished element, regardless of the material it is made of, constitutes the common point of all the finishing operations proposed by Sir.
These operations take place in high-tech cells, where robots collaborate with axis-controlled positioning systems and a wide range of interchangeable tools, sometimes mounted directly on the robots and at other times positioned in a fixed manner. The use of offline programming and dynamic process simulation enables anthropomorphic robots to precisely replicate the movements of an expert finishing operator.
This is why we can assert that Sir’s finishing cells allow for the automation of expertise, as the technical and practical know-how of an operator can be easily transferred to the machine. As a result, robots transform into highly specialized workers capable of flawlessly refining a component, while ensuring consistent and repeatable production quality, paving the way for intelligent robotic manufacturing (smart robotic manufacturing).

Easy Programming

The times needed to put a new article into production are minimised thanks to virtual programming: transferring the operator’s knowhow to the machine is made easy.

Dedicated Hardware

Tool magazines and modules, alignment systems, electric spindles developed by SIR’s design and with multidirectional compensation: solutions’ hardware is the cornerstone of a successful process.

Absolute Quality and Flexibility

Quantities and repetitive tasks are typical of the automation of the past. Using robots in modern process manufacturing means constantly assuring quality, precision and flexibility.

Functional Characteristics

  • Virtual programming
  • Specific tools and spindles
  • Adaptive tool compensation

Post Machining Aluminum Part Finishing

Finishing processes of aluminum elements, such as heads or engine basements.
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Post Machining Cast Iron Part Finishing

Finishing processes of cast iron elements.
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Welding represents the first field of application for robotics and still plays a crucial role, especially in the automotive sector. Sir’s welding lines are typically of a mixed type, meaning they include additional functions such as assembly or palletization in addition to the actual spot or wire welding operation, covering various production stages of the product with a high level of integration. Generally, these lines are oriented towards small batches production with automatic reconfiguration of the line for each batch change. This ensures high flexibility while maintaining the usual product quality and repeatability characteristics.

Turn-Key Solutions

From the equipment design to the stations construction, by way of any secondary processes such as components riveting, screwing or gluing: SIR solutions are a small factory within the factory.

Simplified Programming

The use of modern software simulators makes program writing quick and safe, optimising the robots’ working area and operation final cycle

Total Control

Modern measurement systems for checking workpiece dimensions are combined with three-dimensional inspection of welding beads and spots. Objective, reliable, total quality control.

Functional Characteristics

  • Dedicated equipment
  • Functional integration
  • Virtual programming
  • Metrological and quality inspection

Frame and Half-Frame Welding

Wire welding of complete automotive chassis for low-production cars, combined with riveting and bonding operations.
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SIR is specialized in creating end-of-line automation solutions for product packaging followed by robotic palletization, thereby contributing to optimizing the logistical aspects of modern industrial production. These solutions are applied across a wide range of sectors, including food, beverages, tissue, and ceramics. Furthermore, SIR also offers its expertise in less traditional sectors, such as automotive, where palletization requires unconventional packaging approaches. Moreover, SIR is progressively introducing applications of robotic intralogistics, encompassing both preparation and intermediate palletization during various stages of the production cycle within the same facility. These solutions are also applicable in non-traditional domains like the textile and medical industries.

Production Supervision

Suitable supervision software packages ensure full control of the line’s operation and the traceability of output. Programs and palletizing layouts are controlled using off-line programming techniques.

Dedicated Grippers

SIR’s vast experience in dedicated gripper design allows secure, effective handling of all types of load units, from boxes to bundles and from drums to bottles.

Smart Logistics

Robust calculation software packages combined with end-effectors with 2D and 3D vision systems open the way to the creation of heterogeneous picking systems, the keystone of more effective, customized distribution.

Functional Characteristics

  • Dedicated grippers
  • Production traceability
  • Production supervision
  • Cutting-edge picking

Palletization of automotive items

End-of-line palletizing of items from the mechanical, automotive or general industries.
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Palletization of Batteries

End-of-line palletization of automotive-type batteries using dedicated grippers.
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