Product category:
Testing, analysing and monitoring equipment
News Release from: HBM UK | Subject: MGCpress
Edited by the Engineeringtalk Editorial
Team on 30 May 2000
Press-fit operation monitoring a hit at
Visteon
Six month payback through reduced call-outs and machine stoppages is expected following the installation of HBM monitoring equipment for the press-fit routines in a new automated line
Six month payback, through reduced call-outs and machine stoppages is expected following the installation of HBM monitoring equipment for the press-fit routines in a new type of automated production line The multi-million pound assembly line, built for Ford Motor Company's component division, Visteon in Swansea, uses the press-fit technique which involves precisely manufactured components being pressed together with hydraulic rams
HBM's MGCpress measures the force and displacement during the operation and plots their relationship as components are pushed together.
The resulting graph is calculated and can be displayed in real time to give the operators easy fault finding capability.
With earlier, less sophisticated systems, Johann A.
Krause UK Ltd, a leading systems integrator in the automotive sector, that has designed, built, installed and commissioned the new assembly line, could be called out to a plant for all types of assembly malfunction, regardless of the cause.
MGCpress identifies where the problem is and tells the operator whether the assembly machine, the components, or the hydraulics are at fault.
"From the point of view of avoided call outs and or machine stoppages the MGCpress units will pay for themselves within 6 months," says John Power Project Manager of Johann A.
Krause UK Ltd.
The press-fit technique avoids the use of expensive joining methods like welding, bolting and adhesives, and careful monitoring detects assembly anomalies before they cause damage to the components or the assembly machinery.
In an average modern car there are over 1,400 press-fit actions used in the assembly of the engine alone.
MGCpress uses the 'tolerance window' procedure to keep track of the fitting process.
Each pressing operation is broken down into various stages, or windows, such as threading in, fitting and completion.
Each stage is then allocated a predetermined set of mechanical properties that govern whether the components have been correctly assembled.
If the plot of force against displacement remains within the calculated limits of the window then that stage has been completed satisfactorily and the quality of every assembled item can be tracked and assured.
"We need a monitoring system that will integrate with the plant's modular approach, so that changes can be made to the line very quickly," says Power.
"The MCGpress unit allows the operators to see a pressing signature develop as components are pushed together.
Any anomalies can be identified and rectified before they cause any problems to the assembly equipment or extended interruption of the customers production schedule." "All the machines have pre-configured settings," says Power.
"This makes it very easy for the line to be modified, even if this involves the re-location of an entire machine.
The new line will be manufacturing Power Take Off units (PTOs) for a new 4x4 vehicle that will be manufactured in the United States and Japan.
At the end of the line all the assembly, data is downloaded onto an archive that records the build history for each PTO.
This information can be used in the event of an after-sale component failure to track operational trends and optimise the production process.
The new "Lean Line" will be the first of its type in the UK.
It is based on a Japanese assembly philosophy that enables the operators to discuss the probable cause of any assembly problems and take the appropriate remedial action.
The system prevents the production of consecutive reject assemblies and enhances the quality assurance of the components produced.
The line, which will be capable of producing approximately 800 PTO's per day, is 60m long and consists of 26 individual assembly machines incorporating 15 MGCpress units. Request a free brochure from HBM UK ...
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