Great flexibility in a wide variety of tests

Rosenbauer Karlsruhe GmbH & Co. KG has been part of the Rosenbauer Group since 1998. The company is the group's centre of competence for elevating rescue equipment. At the Karlsruhe site, some 300 employees manufacture turntable ladders and rescue platforms for fire services all over the world.


Rosenbauer Karlsruhe GmbH & Co. KG has been a customer of IGH Automation since 2008. So far, they have installed three mobile AQIs test stands for testing main subassemblies. All the test stands are equipped with AQIs CAN communication to the unit under test, the AQIs test for sequentially running through the test tasks and the AQIs Dashboard module for adjusting and testing in no particular order the functions of the units under tests.


The AQIs test stands at the preassembly quality gates ensure that only faultless subassemblies are installed on the assembly line. This significantly shortens diagnosis and repair times in the event of a fault. All test tasks are parameterised by the company itself.

Benefits to Rosenbauer Karlsruhe GmbH & Co. KG:


  • 100% testing of the functions in cage assembly
  • Tested, preadjusted subassemblies are delivered to the lines
  • The amount of testing and commissioning work is reduced
  • Reduction of diagnosis and repair costs in the event of a fault

Hans-Peter Lörch – Technical Director of Rosenbauer Karlsruhe on AQIs

Why did you need to re-invest in your testing and measuring systems?

Mr. Lörch: We wanted to introduce a computer-supported function testing system in order to obtain consistently high quality of the turntable ladders and to eliminate repeat fault sources.


Why did you choose the AQIs solution over other solutions?

Mr. Lörch: Because of the great variety of our products and the fact that the technical framework conditions are constantly changing, implemented function tests must be parameterisable both in the testing process as well as in the test sequence. AQIs offers that.


What did you want to achieve with the investment?

Mr. Lörch: We wanted to automate the test sequences and to document them with all results for each unit under test, and to save the information so that it can be used for research. A solution for a test station should be conceived and structured so that it can later be extended to other test stations and testing tasks without any problems.


Which of your objectives were achieved thanks to the AQIs solution?

Mr. Lörch: By using the test stands for adjustment work, for quality control and for documentation, we achieved significant time and cost savings in the rest of the production process. The use of AQIs has been particularly successful in the case of cage assembly. AQIs tests 100% of the properties and functions of every cage both fully automatically and semi-automatically. We have to bear in mind that the cage is a very complex and varied subassembly. In the test process, AQIs simulates the vehicle so that the cage works as though it were installed.


The manual test of all cage functions would be very complicated and would have to be performed by a highly-qualified, specialised and experienced colleague. It would not even be possible to manually test some complex functional dependencies during preassembly.


We intend to introduce AQIs test stands for other tasks in preassembly, as well as for the final check and commissioning of the completed vehicle.

© IGH Automation GmbH 2018