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Product information for assembly plants

Module assembly for cooling systems

In the assembly plant product segment, Dunkes was retained by a well-known manufacturer for vehicle air-conditioning and engine cooling systems for a multi-faceted task that could be solved from a single source with several machines from the extensive manufacturing product line. 

The task involved assembling, crimping, and serialising an entire module. The requirements also specified that this activity needed to be performed by one operator.

The workpiece pallets for each station are additionally equipped with a lightcurtain-based insertion control, and, additionally for station 1, with a proximity switch. The pallets are equipped with an automatic clamp, and the processing forces are read with load cells.

Hydraulic table presses from the extensive manufacturing product line with a press force of 63 kN where used as the basis for stations 1 and 3.
Station 2 is a pneumatic riveting and crimping machine with a maximum crimping force of 20 kN.

The machines are installed on a common subframe, and are a equipped with a leakage oil drip pan underneath the machines to comply with Section 19 WHG [German water management act].
All three stations are operated with a common two-handed panel. The entire installation space is secured with a light curtain.

The conceptual design of the extensive processing from a single source proved to be advantageous for this task. This approach allowed the processing of the individual stations and the interfaces of the stations to be accurately matched. 

Station 1 presses a bearing into place. The pressing operation is monitored and documented by a force-distance monitoring facility. The stroke of the hydraulic assembly press can be specified with a programmable cam switch.
A favourable pressing result at station 1 causes the part to be inserted into station 2, a wobble or rolling riveter.
A crimping head in combination with associated contour rollers designed for this task is used to create a positive lock of a sheet metal lid with an aluminium diecast component by crimping the seam. A Dunkes precision wobble riveting machine with adjustable headstock was used for this purpose. For this machinery type, the riveting lead screw mounted into the inside of the cylinder is supported in a highly torsion-resistant manner. The stroke depth of the cylinder can be limited with a mechanical stroke limiter (depth stop), resulting in accurately reproducible output. A force-distance monitor controls and documents crimping process at station 2.
An additional flanged housing is pressed into place at station 3. The press fit is again inspected with a force-distance insertion press inspection. After all 3 processing stations have been completed with an additional outcome, the part is additionally stamped with a facility in station 3.
Processing is no longer possible as soon as one of the three stations detect an assembly defect. The fault must be acknowledged by the operator.