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

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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