Machine No. 6 – pressing the worm onto the gear wheel assembly

Machine with three workstations for pressing the worm onto the gear wheel assembly and laser welding the bearing bracket

Project: Assembly line for the EGR valve – Audi V6 
Number of workstations within the machine: 3
Term of delivery: 2015 – 2016

PARAMETRY:
Šířka: 2800 mm
Hloubka: 2200 mm
Výška: 2600 mm
Hmotnost: cca 1900 kg
Provozní tlak: 0,6 MPa
 

FEATURES:

Teh equipment´s job is to semi-automatically mount the worm to the gear wheel assembly and then place and weld the bearing bracket to the EGR valve´s mounting sheet at two semi-automated workstations. Direct support for these main processes is provided by the preparation of the bearing bracket at a separate, fully automated workplace within the machine.
 

DESCRIPTION OF THE WORKSTATIONS:

Pracoviště DT1
At the DT1 workstation, after the worm is inserted into the press head by the operator, it is automatically pressed onto the gear wheel. After pressing the worm, the operation is completed in the rear part of the workstation by full-circumference laser welding of the screw with the gear wheel assembly.
Control system feedback: camera check of the weld

DT2 workstationAt the DT2 workstation, the bearing bracket with the bush is automatically attached to the mounting sheet subassembly. The bearing bracket is then welded on both sides to the mounting sheet assembly by a laser welding head, and after inspection, the part is passed on for further operations.
Control system feedback: camera check of the weld

DT3 workstation
The DT3 workstation is an automated supporting section of the equipment that ensures the bearing bracket´s autonomous mounting during the pressing of the screw at the DT1 workstation. The final component consists of two parts, which are delivered to the workstation automatically using vibrating feeders.
Control system feedback: monitoring the course of the path and force used during pressing

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Parts of the machine (front side):
b) RM1 main switchboard
c) Operator panel
d) Workstation 1: Mounting the screw
f) Control box with Workstation 1 buttons
l) Camera check monitor
m) Workstation 3: Work area for automatically mounting the bearing bracket
n) Workstation 2: Welding the bearing bracket to the mounting sheet
p) Air treatment unit
q) Control box with Workstation 2 buttons
s) Connecting the exhaust of the work areas

Parts of the machine (rear side):
a) Side door for access to Workstation 3 
b) Vibrating bracket hopper
c) Vibrating bushing feeder
d) Vibrating bearing bracket pre-feeder
e) Rear door for access to Workstations 1 and 2

DESIGN OF THE MACHINE:

• Robust steel frame with closed rails for ease of handling with a forklift,
• Solid/polycarbonate panels – as fixed surfaces or as doors
• Workspaces are secured with optical security barriers, electric security locks, or bolted connections
• The operator panel is part of the electrical switchboard,
• Control buttons for DT1 and DT2 workstations within easy reach of the operator, the monitor with the results of the welding camera check located above the DT2 workstation
• Connecting the machine to the exhaust system of the work area and integrated air treatment unit