Machine No. 5 for installing the ball bearing to the mounting sheet
No. 5 machine of semi-automated production line for assembly of 3rd generation Audi EGR valve with subsequent adaptation for the alternative assembly of the 2nd generation EGR valve.
Machine with two workstations for:
– installing the ball bearing to the mounting sheet
– mounting the gear wheel stem assy and spring to the mounting sheet subassembly with the ball bearing
Project: Assembly line for the EGR valve – Audi V6
Number of workstations within the machine: 2
Term of delivery: 2015 – 2016
PARAMETERS:
Width: 2200 mm
Depth: 1390 mm
Height: 2000 mm
Weight: 1100 kg
Operating pressure: 0.6 MPa
FEATURES:
The job of the machine and its workstations is to place and weld the ball bearing to the mounting sheet at one workstation, and at the other the machine completes the configuration with the spring and gear wheel assembly.
DESCRIPTION OF THE WORKSTATIONS:
DT1 workstation
The DT1 workstation cleans the ball bearing of its oil film and welds it to the mounting sheet. The machine operator inserts the mounting sheet into the clamping unit, the workstation automatically delivers, cleans, places and welds the bearing to the mounting sheet using a V-weld. After welding, the bearing´s correct function is verified, and the assembly is pushed back to the operator.
DT2 workstation
The DT2 workstation completes the mounting sheet with the bearing from the DT1 workstation with other components, consisting of the spring and gear wheel assembly. The operator first places the individual parts in a specified sequence on the mounting sheet subassembly clamped to the fixing jig. The workstation automatically performs the pre-suspension and centering of the spring inside the fixing points and then presses the gear wheel assembly and spring into the ball bearing on the mounting sheet as far as they will go.
Machine parts:
a) Front door to the ball bearing cleaning space
b) DT1 workstation: Welding the the bearing to the mounting sheet
c) Control box with Workstation 1 buttons
g) Camera Check Monitor
h) RM1 main switchboard
i) Operator Panel
j) DT2 workstation: ASM MOUNTING SHEET SUB-SPRING-GEAR WHEEL ASSY subassembly
k) Control box with Workstation 2 buttons
m) Optical safety barriers
DESIGN OF THE MACHINE:
- Robust steel frame with closed rails for ease of handling by forklifts,
- Solid/polycarbonate panels – as fixed surfaces or as doors,
- Workplaces secured with optical safety barriers, electric security locks or bolted connections,
- The operator panel is part of the electrical switchboard,
- The control buttons of both workstations easily reached by the operator, the same as the monitor with the results of the welding camera check,
- Connecting the machine to the work area exhaust system.
