The project involved designing and building an advanced pressing machine for shaft assembly, incorporating automatic greasing for various components. The machine needed to handle shafts with different components and automate the unloading process while ensuring precise alignment during assembly. The objective was to enhance production efficiency, maintain consistent quality, and meet stringent industry standards for safety and performance.
Special Purpose Machines
Greasing & Pressing Assembly
Our client, a leading Tier-1 supplier with over 45 years of experience in automated assembly systems, excels in vertical manufacturing. They offer expertise in custom automation assembly systems, including fixed, programmable, and flexible automation, ultrasonic welding, and comprehensive support services.
Scope
Challenge
The system required fixtures for assembling shafts into slip yokes, crimping, and electrical sliders, along with a grease pump and HMI. It needed to accommodate components of varying sizes and geometries, requiring precise adjustments and flexible handling. Ensuring accurate grease application was crucial for optimal performance. Reducing cycle time while increasing throughput without sacrificing quality was a primary concern. The fixture had to be durable enough for continuous operation and minimize maintenance downtime.
Solution
Our team developed an advanced pressing machine that met the project’s requirements and addressed its challenges effectively.
The machine features two distinct fixtures for shaft and spline yoke assembly, mounted on a sliding unit with an electrical slide. Adjustable clamping units secure components during the greasing and assembly process. The operator manually loads components into the fixtures.
A bridge assembly, including a crimping tool with LVDT and a pick-and-place mechanism, accommodates varying shaft lengths. An HMI, electrical slide, pneumatic cylinders, FRL, sensors, safety light curtains, grease pump, and printer control various functions as needed.
The spline yoke is placed in a grease filling station fixture, where an automatic grease pump applies the precise amount of grease, ensuring consistency and preventing over- or under-greasing. After greasing, the yoke is unloaded and placed into the assembly fixture, where an automated mechanism handles parts gently to prevent damage or misalignment.
The assembly cycle begins with the operator pressing the Cycle-Start button. The shaft assembly moves towards the slip yoke with the required force and distance. Pincer units, equipped to move vertically and horizontally, align with the boot clamp and spline bar assemblies. An LVDT linear scale verifies and maintains positioning.
The machine ensures proper boot positioning before crimping boot clamps with a force of 4000N ± 200N. Pneumatic cylinders manage automatic unloading, distributing assembled components onto a conveyor. The system’s design allows easy integration and future fixture upgrades.
Real-time monitoring with sensors ensures each part meets quality standards, with deviations detected and corrected or rejected promptly. Safety and ergonomic standards were meticulously followed, and all aspects of DFMEA (Design Failure Modes and Effects Analysis) were considered. The cost-effective design enabled continuous operation, boosting productivity.
Value and Benefits
The integration of advanced technology and streamlined processes significantly improved efficiency, reducing cycle time and boosting throughput to meet high production targets. The system’s precise adjustments and flexible handling accommodated various component sizes and geometries, ensuring optimal grease application and precise alignment. Automated unloading minimized damage and misalignment, while the robust design reduced maintenance downtime. The adaptable fixture allowed for easy future adjustments. Automating the process enhanced safety and ensured high-quality, consistent products, showcasing our commitment to innovative automotive manufacturing solutions and positioning our client for future success.
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