Exhaust gas return (EGR) pipe assembly line

Two identical robot cells (one for pre-assembly, the other for final  assembly) assemble a variety of EGR pipes for motor vehicle engines. Each cell has 5 docking stations containing different mobile machining units depending on the current application. A camera system at the end of the infeed buffer conveyors ensures that the robot grippers are correctly positioned for picking up the parts. The part transport and the cycle sequence are controlled by the robots to match the part type. At the pre-assembly station, the unmachined pipe is fed into the pipe cutting station. The pipe proceeds to the flanging station where a flange is attached to the flanged end and soldering paste is applied at the contact points. At the final assembly station, the pre-assembled, soldered pipe is fed to a bellows bending station where the bellows is bent to size on a 3-axis, NC controlled bending system. At the end of the assembly cycle, each pipe is measured from end to end by another 3D camera system. Pipes tested as OK are fed out and stacked in boxes, ready for delivery. 

Test Bench for Valve Stroke Adjustment

This machine is used to check the valve stroke of a cylinder head. The test part is mounted on a special pallet. The precise and accurate measurement of the valve stroke is performed by a special sensor. The adjustment of the excentrical shaft, which is responsible for the valve stroke, is carried out by a control unit. It is a semi-automatic machine with automatic testing and manual loading and unloading. For extreme requirements, the test part also is supplied with oil.


Calibration and Test Bench

The parts to be calibrated are combined pressure & temperature sensors for the automotive market.
The calibration and test bench can accommodate up to eight assemblies. These sensors are calibrated and tested in air in a maximum temperature range from -40°C up to +150°C. The bench is designed for a pressure range of 0.5 to a maximum of 40 bar absolute. For accurate temperature control we use a temperature control unit. The temperature can be regulated in a range between ±0.1°C. The calibration and test procedure is fully automatic. The temperature and pressure levels are given by an external control system which communicates with the PC of this bench. The testing process begins with setting up the desired temperature. If the temperature is stable, the pressure steps will be set. After some stabilization time, the assemblies are calibrated and checked. If the cycle is completed, the station opens and the sensors can be unloaded.
After calibration the modules are tested either if they are OK or NOK. Depending on the type a seal ring check is carried out with a camera. Modules which are tested as OK can be marked with the integrated laser which provides the customer logo and a serial number. NOK modules are covered with a specially created error label and dropped at the integrated error box.

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)

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