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Accumulator Assembly and Test Line

The assembly and test line is designed to assembly and test so called accumulators. The line consists of several semiautomatic stations with manual loading and fully automated assembly / test sequence.

Assembly and test steps:

• Pre-assembly of piston
• Oiling of piston
• Assembly of piston and housing together with nitrogen filling
• High-pressure leakage test
• Functional test / marking of accumulator
• O-Ring assembly
• External leakage test.

The line is built for assembly of two different types of accumulators.

Pump Assembly and Test

This production line assembles and tests oil pumps. It is designed as a semi-automatic unit and consists of two separate modules.

The following work steps will be performed:

Assembly module:

• Pressing-in of the pins into the pump body
• Manual loading of the workpiece carriers with all components of the pump
• Visual inspection of the components (presence, type identification, position, etc.)
• Automatic assembly of the pump

Test module:

• Pressing-in of the seal (manual mounting)
• Visual inspection of the seal (manual mounting)
• Automatic transport to the following stations
• Air leak test
• Run-in station
• Test station
• Marking station
• OK/NOK output rail

GDI FRA Hydraulic Pulse Test Bench

For the development and quality assurance for production of high-pressure injectors and rails it is neccessary to examine the lifetime and stability. The pulsation test bench has been designed to check these properties for the individual components.
On the monitor the actual pulsation sequence is displayed. The test rig can be equipped individually.

EOL for E-Motor

End Of Line for testing the behavior of brushless motors. The motors pass 6 different test stations on workpiece carriers transported by a belt system.

BEMF station: Measuring and evaluating the electrical properties of the motors (hall-, optosensors, winding properties).

Run-in station: Burn-in test to spread the grease inside the bearings in order to achieve more stable running and easier start. Another goal is to face the motor with heavier conditions.

Vibration station: Measures the motor vibrations under real conditions (analysis software in collaboration with the University of Ljubljana).

Imbalance station:  Measures the imbalance of the motors under real conditions (collaboration with an external imbalance specialist) .

Torque station: Measures the torque of the motors while stressing them with an eddy current brake.

Run-out station: Measures the concentric of the motors relative to the center of rotation via Keyence 2DMicrometer.


Test of Pressure Limiting Valves

The machine has been designed for testing pressure limiting valves. Therefore, frequency controlled pumps generate a constant flow. Depending on the valve a certain pressure will be reached in the system. This pressure is characteristic for this particular part.
The machine is loaded by an operator. He inserts and screws the part into a nest which is located on a rotary table with a torque controlled pneumatic screwdriver. By pressing the foot switch the operator indicates the rotary table control the readiness. As soon as all operations on the rotary table have been finished, the table will turn. Now, the untested parts will be fed to the dedicated stations and will be tested or marked. Finished parts will be screwed out by the operator taking in account the “GREEN/RED Status” lamp.

Assembly Bench for Gasoline Cold Start System

The machine is a fully automatic assembly and test bench. It has a round table with 11 substations. The performed activity is the assembly and test of a cold-start-system for Bio-Ethanol cars.
This cold-start-system consists of a common rail with 4 injectors.

Process description:

• O-Ring assembly
• Injector assembly
• Airleak test
• Airflow test
• Flow and spray angle test with test medium
• Laser marking


废气再循环系统-管组装

 

两个一致的机械手单元可以对多种不同类型的废气再循环系统-管道进行预先安装和最终安装,这些管道被应用于汽车的尾气返回。每个机械手单元提供5个加工对接位置,在这些位置上,根据应用类型,能够对接移动的加工工位。供给缓冲带末端上的摄像系统确保了机械手夹爪的正确位置。零件传送和运行控制都会由机械手按照其类型进行管理。在预安装单元区,原料通过管切割工位整修,在最后通过法兰工位上装配法兰之前,同时在接触位置上粘贴焊料。最终安装单元借助一个数控三轴系统,在管弯曲工位上按尺寸弯曲预先安装并粘贴过的管。同时进行一个泄漏检测。然后每个管都会从一端到另外一端,借助照相系统测量出一个三维图形,然后合格的零件被大量地放置在运送箱内。

气门升程调节的检测台 (平衡检测)

 

此设备用于检测气缸盖里的气门升程。检测件被装在特殊的工装上。通过一个特殊的距离测量传感器可对气门升程进行高精度,准确的测量。

偏心轴对于气门升程来说是关键,可通过一个控制器对它进行调节。

此设备为一个手动上下料,全自动化测量的半自动化设备。

当有极端要求时,检测件也可以使用油供应。

 

校准和检测台

 

在汽车工业中需要校准的零件是压力传感器和温度传感器。

校准工位和检测工位能够最多添加至8组零件。这些传感器在一个最大温度区域为-40°C到+150°C内使用温控空气进行校准。此设备的绝对压力值区域为0,5 bar到40 bar。

对于精确的控温,温度要位于±0,1°C的精度范围内,因此Huber品牌的调温器会被使用。

校准过程或者检测过程都是全自动化过程。温度级别和压力级别包含外接检测电脑的控制,这些都可以通过控制进行信息交换。

检测运行在预先设定一个期望温度后开始。当它处于稳定时,检测压力会被调节。在已知的稳定时间后,组件被校准或者读取。循环结束时,工位打开,组件被取出。

校准的组件然后在手动工位上做合格检测。根据其类型也可以额外借助相机进行一个密封圈检测。

如果组件合格的话,会由集成的激光在零件上打印出用户商标和一组序列号。不合格件则被贴上各自的生产错误标签,放到集成的废料箱内。

Sonplas GmbH- Sachsenring 57 - D-94315 Straubing - Deutschland - Tel: +49 (0) 94 21 / 92 75 - 0 Fax: +49 (0) 94 21 / 92 75 199 - info(at)sonplas.de

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