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Fluid Filling FASprofill

Survey : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :32 - 33

System Elements Professional-/ Premium Line : : : : : : : : :34 - 35

Filling Systems Structure : : : : : : : : : : : : : : : : : : : : : : : : : : 36 - 37

Complementary Products : : : : : : : : : : : : : : : : : : : : : : : : : 38 - 41

Assembly Equipment FASsembly

Survey : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 42 - 43

System Elements rear axle setting station : : : : : : : : : : : : :44 - 45

Axle Assembly and Setting : : : : : : : : : : : : : : : : : : : : : : : : 46 - 47

System Elements Body Chassis Marriage : : : : : : : : : : : : : 48 - 49

Body Chassis Marriage : : : : : : : : : : : : : : : : : : : : : : : : : : : 50 - 51

System Elements Wheel Alignment in the Assembly Line 52 - 53

Wheel Alignment in the AssemblyLine : : : : : : : : : : : : : : : :54 - 55

Lifting Device : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :56 - 57

Module installation : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :58 - 59

Glass roof installation/ Glazing : : : : : : : : : : : : : : : : : : : : : : 60 - 61

Filling, Testing and Assembly

of Vehicle Components : : : : : : : : : : : : : : : : : : : : : : : : : : : 62 - 63

Final Assembly

32

The performance and quality of

components such as power

steering, radiator, ABS, brakes,

clutch, engine, gears and air-

conditioner is mainly determined

by the exact filling with fluids.

Systems from Dürr Somac

provide you with the entire

spectrum of modern fluid filling

systems for vehicle construc-

tion: from individual systems

for assembly lines with cor-

responding synchronization

through to combined filling

systems and right up to mobile

systems. Our employees at

Dürr Somac, have many years

of experience in the construc-

tion and manufacture of fluid fil-

ling systems and manufacture

of fluid filling systems and

testing equipment gained

through more than 1000 machi-

nes installed so far. The range

of supply also includes supply

equipment, control and visuali-

sation systems, communication

systems for vehicle control

units and various automation

levels. A high standard of deve-

lopment and the continual dia-

log with our customers are your

guarantees of our top technolo-

gy combined with practical

know-how. Experienced Dürr

Somac teams work with your

project teams on simultaneous

engineering projects to find

individual to find the optimised

solution to your individual filling

task.

The Main Filling Methods

Dosing Filling Brake Bleeding

33

Filling Equipment FASprofillSurvey

The vacuum-pressure filling isused in all complex filling taskswith vacuum-resistant sys-tems. The system to be filled isemptied and checked for com-plete tightness. Controll-ablepressure allows the filling pro-cedure to run evenly.Afterwards it is topped off tothe maximum reservoir level.

Application:

BrakeClutchRadiatorPower steering systemAir conditioning system (Vacuum-mass metering)

To fill the system, a definedamount of fluid is filled underpressure into the system. Theamount of air displaced by thisprocess either escapes throughthe reservoir opening or isextracted. A variation is thelevel filling whereas the fillingprocess stops when the requi-red filling level is reached.

Application:

Engine, gearboxFuel tankParticulate filterWindscreen washerHydraulic system

Bleeding is used with non vacu-um-resistant systems or in caseof already partly filled systems.The medium is filled underpressure into the reservoir untila defined level is reached. Thesystem is de-aerated throughrelieve openings.

Application:

In rework area

Vacuum-Pressure Filling

Field of Application

Brakes /ABS

Radiator

Power steering

Windscreen washer system

Air-conditioner

Clutch

Gearbox

Engine

Fuel tank

Diesel particulate filter

Off-road stabiliser

Suspension system

34

Control System

Base Unit

Travelling Unit

The console is directed along the assembly line parallel to the vehicle by the travelling unit. This is done either by mechanical adjustment or by a servomotor with synchronisation.

Adapter

The filling adapter is the interface between the system and thevehicle and is characterised by its ergonomic construction, user-friendly arrangement of the start/stop buttons on the handle andits absolutely drop-free operation. Automatic and semi-automatichandling systems are available to aid the worker in easily positio-ning the adapter.

Console

The movable console allows fast, user-friendly and flexible input and adjustment of the process parameters. The integratedvacuum pump guarantees short evacuation times, an optimalfinal vacuum and a fast filling cycle.

The stationary base unit monitors the most important processdata. Its integrated storage tank with automatic filling level con-trol saves valuable space. Interfaces between the filling systemand the tank container are not required.

The filling systems are controlled by PLC or PC. Using the PCallows functions in addition to ABS control, such as visualisationof the course of the process, statistics and connection to thenetwork.

35

Filling Equipment FASprofillSystem ElementsProfessional-/ Premium Line

Supply Equipment

The system can be supplied with all required media from barrelsor via a central media supply. Media to be provided are, e.g. brake fluid, oil, glycol, washer fluid additive, fuel and refrigerant.Combined stations for engine cooling water and washer fluidguarantee exact mixing.

Automation

Different automation levels for adapter handling and processexecution are available from simple adapter presentation to fullyautomatic filling systems.

Communication with the Control Unit

Parallel to the filling process, the brake filling system with ABScontrol simultaneously establishes communication to the ABSsystem and carries out control and test functions. There are alsointegrated solutions for communication with additional vehiclecontrol units such as the driving dynamics controller and theautomatic clutch system.

Determination of Water Content

This system allows a continuous, maintenance-free measurement of the water content in the brake fluid.

Brake Fluid Treating Equipment

The brake fluid treating equipment reduces the water content of the brake fluid to a minimum. The treating is done by evacuation.

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Compact Mobile / Compact Line

For slowly running or clocked assembly lines, in rework area and in pro-duct testing department

Cycle time t ≥ 2.5 min.

Hydraulic and control concepts for highest qua-lity requirements

Swivelling arm for adap-ter, printer, barcode reader, OBD plugs

Optional design as line equipment: • with rail system, optio-nal with motor drive

• due to installation of all components in the con-sole no further space requirement along the line

Professional Line / Premium Line

For fast running assem-bly lines

Cycle time t ≤ 2.5 min.

For highest quality requirements and specialplant specification

Full range of features and automation grades available

Separate electric cabi-nets and hydraulic base units for best conditions for maintenance and repair

Combined SystemMulti Compact

Combination of several media as well as several consoles

Practical combination ofseveral filling proces-ses, e.g.:• radiator + power steering + windscreen washer

• brakes + air conditioning

For large scale pro-duction

Selection Criteria for Efficient Combinations

Assembly progress of the vehicle within the filling cycle

Process and handling time for the individual systems to be filled, e.g. ABS system

Space conditions on theassembly line

Carrying capacity of the assembly floor and the steel structure

Advantages of Combined Systems:

Saving of production time due to simultaneous filling

Combination of similar technological processes

Space saving on the assembly line

Lower investment costs for subassemblies

Essential

Vacuum-pressure filling for slowly running or clocked assembly lines and CKD plants

Cycle time t > 3 min.

Standard equipment for brakes, power steering and radiator with drum supply

Optional ABS control available

Partly manual control available

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Filling Equipment FASprofillFilling Systems Structure

Dürr Somac filling systems

have a modular design and can

be easily integrated into existing

production processes without

any problem. The modular

design guarantees their flexible

adjustment to the specific

requirements of our customers,

provides the highest level of

process reliability and facilitates

maintenance and repairs.

Your Advantage

Ergonomic fill adapter

Process reliability

Short cycle times

Absolutely drop-free

Cleanliness

Easy to operate

Survey of System (Standard Configuration)

Base Unit

Drum pump station

Hydraulic cabinet with supply tank, filling pump and vacuum pump

Control System

Electric cabinet with PLC and operator panel

Electric cabinet with PC control

Console

Operator panel

Hydraulic unit with vacuum pump, vacuum and pressure measurement

Travelling Unit

Suspension with double-rail system

Trailing cable installation

Automatic synchronisation of console with conveyor

Pneumatic drive, friction gear or tooth-belt

Adapter

Adapter head with pneumatic clamping

Quick-connection plate for adapter

Miscellaneous

ABS control or other control devices

Statistics (only with PC control)

Network connection

Printer, barcode reader

Combination of different media

Adapter handling

Compliance with special plant specifications

Dimensions [LxWxH in mm]

Base unit/electric cabinet combination

Console

* in case of Compact Line: Base unit and control system complete as console in rail system

Essential

+

+

+

-

-

-

-

-

-

-

+

-

optional

-

-

-

-

-

-

1100x600x1300

-

Compact Mobile/Multi Compact

optional

+

+

optional

optional*

optional*

optional*

-

optional

optional

+

+

optional

optional

optional

optional

op. (radiator/windscr. washer)

-

optional

1300x800x1500

-

Professional-/ Premium Line/Combined System

optional

+

+

optional

+

+

+

+

optional

optional

+

+

optional

optional

optional

optional

optional

optional

optional

approx 2800x600x2000

approx 1000x600x1360

38

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This system allows to determine

with high precision the water

content in brake fluid at the

measuring point (e.g. at the cen-

tral supply station, in the filling

station before the filling point in

the vehicle or in a circle of seve-

ral linked brake filling stations) as

well as to indicate and print out

the measuring result. Instead of

time-consuming boiling-point

measurement or Karl-Fischer-

Titration, that each only allow

sample testing, the photometer

system allows continous, main-

tenance-free measurement.

This system, especially de-

veloped for the automobile in-

dustry, eliminates risks concern-

ing brake reliability - risks that

can occur when smallest

amounts of water infiltrate into

the system during filling proces-

ses.

Your Advantage

Continuous measurement during production with online display

Early warning at central supply stations

Guaranteed use of brake fluid according to the quality requirements

Enables documentation of the brake fluid quality filled into the vehicle brake system

Technical Specifications

Type Version Measuring Accuracy Reproduci- Temperature De- Drift Pressure Re-Range (%) (%) bility (%) pendence (%/°C) (%/°C) sistance (bar)

WGB 500 External UnitWGB 1000 Internal Unit 0-0,5 ±0,03 ±0,01 <0,01/10 <0,01/24 10

Water in Brake Fluid – an Avoidable Safety Hazard

External Unit WGB 500 Internal Unit WGB 1000

The Application

Stationary at the outlet ofa central supply unit

Stationary at a brake fluid treating equipment

At the assembly line for monitoring the brake fluid of several filling systems

Integrated in the base unit of a filling system

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Fluid Filling FASprofillComplementary products

Supply devices

Central media supply Drum pump station for the supplyof e.g. brake fluid, coolant fluid orhydraulic oil

Test devices for filling equipment

Vacuum measuring kit for thecheck and verification of vacuumand pressure sensors of filing sta-tions and recording of measuringseries at wheel brake cylinders

Test facility for vacuum and fillingfunction

Diesel / Fuel bleeding equipment

Diesel bleeding device to improvethe first engine start in theassembly line

The Application

Fluid treatment

Determination of water content

Determination of glycol content

Brake fluid conditioning

Humidity measurement

Complementary equipment

Supply equipment

Mixing equipment

System test equipment

Diesel/fuel bleeding equipment

Gas condensation

Communication

Control unit communication,vehicle diagnostic (ABS, EDS, FDR, ESP, AKS etc.)

Management systems

Data concentrators

Networking

x-line visualisation

Automation

Adapter handling

Semi-automatic systems

Fully automatic systems

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To make cars safer and more

comfortable, the variety of in-

stalled control systems (ECU’s)

is continuously increasing.

Therefore more and more sys-

tems to be filled are equipped

with an ECU. These control

units have to be actuated du-

ring the filling process in the

assembly line. A brake filling

station, for example, is connec-

ted to the ABS interface and

controls the sequence of opera-

tions to achieve a correctly filled

brake system.

Clutch (AKS)

ABS / EDS / ESP / FDR

Power Steering

Auxiliary Air Conditioning (trucks)

Fuel Pump

Off-Road Stabilizer

Suspension System

Off-Road Stabilizer

Suspension System

For the communication with

ECU’s several different interfa-

ces are available which are part

of an open ECU control system

and thus are easy to modify and

adaptable to various ECU’s. (For

further information please refer

to chapter “FAStronic – Mobile

Diagnostic devices”).

Depending on given conditions,

different diagnostic plugs can be

used to connect the vehicle

with the diagnostic interface

(for further information please

refer to chapter to chapter

“FAStronic – Connector

Systemsto chapter“).

Control Unit Communication

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Fluid Filling FASprofillComplementary products

The Functions

Vehicle identification

Vehicle positioning or conso-le synchronisation

Handling systems for the adapter presentation

Automatic filling

Determination of process data (set and actual value comparison)

Storage of the results

Vehicle release

Your Advantage

Cost-efficient through less personnel expenses

Higher safety standard

Ergonomics

Handling Systems

Handling systems make it easier forthe operator to adapt and removethe adapters and thus shortenhandling times. The adapters arepresented near the fluid reservoirsvia handling arm with one or twoaxes. Only the adaptation itself,starting the filling process andremoving the adapters afterwardsare still operator’s tasks.

Semi-automatic filling systems

Semi-automatic filling systems faci-litate the adaptation via the pre-positioning of the adapter right nextto the fluid reservoir as well as theautomated lifting and depositing ofthe adapter at the end of the fillingprocess. They save time for theoperator that he can use for othertasks.

Fully automatic filling systems

Fully automatic filling systems exe-cute the whole filling process auto-matically up to the return of theequipment. Besides the savingspotential they also consider particu-lar ergonomic requirements.Additionally they enable the comple-te enclosure of the safety zone forthe filling of fuels.

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Our many years of practical

experience in the construction

of complex assembly systems is

the basis for the success of our

products. The continual dialog

with our customers is the pre-

requisite in solving problems,

allowing us to offer complete

systems at first hand. We use

modern automated-system tech-

nology in our assembly systems

and we ensure the high quality

of our products by reproducible

assembly conditions. Based on

your assembly requirements, our

assembly systems are planned

above all to be rational in func-

tion with an automation adapted

to your needs, providing high

efficiency at an attractively low

price.

We are used to thinking holisti-

cally and with an eye to future

requirements. Our range of ser-

vices in the field of assembly

technology covers all of your

requirements. This starts with

the planning of the entire

assembly and ends with the

training of your personnel, and

also includes the maintenance

and servicing of our systems.

Our range of products includes

manual, semi-automated and

fully-automated assembly and

adjustment stations for axles

and for assembling and for

fixing the drive and wheel units

in the vehicle bodies. We also

offer additional manual and auto-

matic handling and assembly

equipment as well as lift trucks,

lift tables, pallet skids and work-

piece carriers (pallets).

Another focus of the product

range are mechanisation solu-

tions for the installation of pre-

assembled modules, such as

cockpits, frontend modules,

tanks etc. as well as systems

for the automated fitting of

windows and glass roofs. We

also provide customised equip-

ment for the finalisation of

vehicle modules which com-

bine different processes such

as filling, testing and assembly.

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Assembly EquipmentFASsemblySurvey

Product Field Front and Rear Axle Assembly Line

Conveyor equipment

Pallets

Manual and automaticbolting stations

Manual and automaticmeasuring and setting stations for axle geometry systems (toe, camber and castor) at front and rear axles

Pre-assembly of

- Anti roll bar

- Steering gear

- Suspension struts

- Swivel bearings

- Shock absorbers...

Product Field Body Chassis Marriage

Conveyor Equipment

Pallets

Lift Trucks

Lift Tables

Manual and automaticfitting stations

Manual and automaticbolting stations

Manual and automatic chassis measuring andsetting stations

Product Field Module Installation & Adhesive Application

Cockpit

Frontend

Tank

Cw-subfloor

Spare-wheel trough

VIN marking

Glass roof

Front, rear and side windows

Our Service

Engineering Assembly /Commissioning

DesignTraining

ManufactureService and Maintenance

Your Advantage

State-of-the-art technology

Automation concept adapted to your needs

High-quality, robust products

Low maintenance and repair costs

High level of availability of systems

Low piece costs

Optimization of initial start support

The Application

Axle assemblyand setting

Body Chassis Marriage

Wheel alignment

Module installation

Glass roof and window assembly

Filling, testing and assembly of vehicle components

44

Identification

Axle lifting unit

Axle clamping devices

The axle clamping devices keep the rear axle in a defined position andsimulate the later assembly condition of the rear axle in the car body.The axle clamping devices support the spring forces which are inducedinto the axle during the operating sequence. The axle clamping devicescan be driven hydraulically or pneumatically.

The wheel hub support

The wheel hub support consists of a support for the rear axle which islocated on a floating plate and can be rotated horizontally. The floating plates guarantee that no tension is induced into the chassis. Moreover the wheel support grants a free translation and rotation of the wheelduring the toe, respectively camber, setting. The rear axle can be driven by the wheel hub support during the measurement. There are various possibilities for the support of the wheel hub: wheel support with a pair ofrollers with and without adapter disk, wheel support with hub grippingsystem, wheel support with supporting prism.

Alignment unit

The alignment unit positions the rear axle in such a way that it’s axis ofsymmetry corresponds with the axis of symmetry of the rear axle settingstation. The rear axle is located via two locating bore holes provided forthis purpose. In this way the axle is in fixed and steady position during the loading and setting.

The axle lifting unit transports the rear axle into the machine and unloads it again, after the completion of the setting sequence, onto the conveyingsystem. The axle lifting unit can be driven hydraulically, pneumatically or electrically. It is either integrated in the conveyor or in the rear axle setting station.

The identification recognizes the rear axle and transmits all necessarytype-specific data to the machine so that it can be set to suit the speci-men. By means of the identification the designated setting values of theaxle geometry are transmitted to the setting system. There are 4 pos-siblities available: Manual entry, reading of a barcode on the axle, Moby M, calling up data from the host computer via the axle sequence.

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Assembly EquipmentFASsemblySystem Elements Rear Axle Setting Station

Spring load unit

The spring load unit loads the rear axle with a defined spring force in order to simulate the later assembly condition of the axle in the carbody. This load corresponds with the weight of the vehicle in an assembled condition and is induced into the axle by pneumatically, hydraulically or electrically driven actuators.

Documentation

At this stage, the parameters of the vehicle geomety before and after the setting process are documented considering the vehicle ID-number. Besides the storage, statistical evaluations are possible as well.

Axle geometry setting system

The setting of toe or camber values on the rear axle can be realizedmanually, semi-automatically or fully automatically. During the manualsetting the operator controls the related axle geomtry parameter bymeans of a display which shows the difference between the actual andthe desired value. During the semi-automatic setting the operator adaptsa setting tool which controls the the angle of toe and camber by theinput difference between desired and actual value. During the fully auto-matic setting the adaption of setting tools also is realized automatically.

Axle geometry system

The axle geometry system consists of two measuring units which will be lo-cated in front of the wheel supports of the rear axle. These units acquire theaxle geometry parameters. The measurement is realized by mechanical sen-sors or by non-contact laser measurement system on a measurement sur-face, especially designed for this purpose. During the setting, the axle geome-try system is able to acquire the angle of toe and camber on the rotating orstationary wheel. The axle geometry measurement system is calibrated by amaster gauge which describes defined angles of toe and camber close tozero.

Load unit

Before the rear axle is measured and adjusted the load unit lifts the wheelhubs against the spring force in z-direction. In this way the rubber bushesin the axle settle. In a second step the axle can be lifted to a defined height in order to simu-late the later spring compression condition. Different spring compressionconditions of the rear axle can be simulated by the z-stroke of the loadunit. The load unit can be driven by pneumatic, hydraulic or electric actua-tors.

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The axle assembly is carried

out in accordance with all type-

specific derivatives. In order to

prepare the axle assembly all

relevant components are sub-

assembled: anti-roll bar, diffe-

rential, shock absorber, com-

pliance bushes etc. The axle, its

components and some smaller

parts are fed to the pallet accor-

ding to their type-specific deri-

vatives. The axle is fitted on

the pallet and conveyed to the

automatic bolting station and is

bolted. The bolting process is

finished, the axle is transferred

into the automatic setting sta-

tion. Here, axial run-out, toe and

camber are measured, the mea-

surement values are evaluated,

the axle is set and the values are

documented.

47

Assembly EquipmentFASsemblyAxle Assembly and Setting

Your Advantage

Minimum piece cost due to:

• System technology adapted to your product

• Degree of automation determi-ned according to financial pre-requisites & quality standards

• Minimum surface area

Enhanced quality by optimized processes

High availabilitydue to:

• Low failure rate• Short maintenance

and repair periods

Minimum initial start periods

The tasks

Elaboration of integrated overall conception by colla-boration with specialized departments of customer (planning, design, main-tenance, production)

Subassembly of components

Assembly of several derivatives

Integration of automatic processes

Presetting of axle geometry values

Documentation of bolting connections that are relevant with regard to safety

JIT transfer to final assembly

Ergonomic working environment

Pre-assemblyanti-roll bar

Pre-assemblywheel carrier

Conveyor System

Automatic BoltingEquipment

Toe/Camber measu-ring and setting

station

Modular Structureof Rear Axle Assembly

Rear axle setting station

Pallet

Pre-assemblycompliance

bushes

48

Documentation

Pallet

Conveyor System

The conveyor system transfers the components with the help of the pallet (front axle,rear axle, exhaust, engine, brake system etc.) into the assembly system, when themarriage is finished, it carries the vehicle out of the station. It has to be designed insuch a way, that it can carry the weight of the pallet and the components. Prior to thetransport to the marriage station, the system checks whether the station is idle toavoid collisions.

Identification

The identification system is to identify the vehicle and determine thesequence of assembly with reference to this vehicle. There are severalmodes of identification: manual input, data carrier, barcode, mechanicalcoding and initiators. The identification system enables the correctassembly of the body with its corresponding chassis and components.

The pallet is used as an assembly aid. The pallet must be designed insuch a way, that the components can be nested and their weight carried. The design must support easy feeding and assembly of thecomponents. With the help of the pallet the components are trans-ferred on the conveyor system. The pallet is also equipped with items that enable vehicle identificationsuch as a barcode label. Typical components transferred on the palletinclude the rear axle, front axle, the entire drive unit, the fuel tank, thebrake system with pedal unit and ABS block, drive shaft, heat pro-tection shields and exhaust system, and others. These components are mechanically and electrically connected witheach other via brake pipes, tank pipes and ABS cable tree.

The bolting results are documented with reference to the vehicle identification number. Further to simple archiving it is also possible to carry out statistical evaluations.

49

Assembly EquipmentFASsemblySystem Elements Body Chassis Marriage

Nutrunner Equipment

The nutrunner equipment fastens the bolts according to a pre-defined torque and angle value, the bolting results are provided for documentationpurposes. The nutrunner equipment is to nest the bolt into the wrench(exact positioning) and to compensate for positioning tolerances of thebolting points. The nutrunner spindle can be driven either electrically or pneumatically.

Nutrunner Transfer Mechanism

The nutrunner transfer mechanism aligns the nutrunners with body and components. This process is carried out manually or automatically by simple designed drives or by robots.

Positioning

With the help of camera systems, brackets, photo eyes or lever armlimit switches the position of components or interfering edges can becontrolled or measured and provided as data. Thus, an exact positioningof the components within the marriage station can be guaranteed.

Fitting Facility

When the transport to the fitting station is carried out, the pallet musthold the components, i.e. engine, brake system, fuel tank etc., in a definedposition. The conveyor system, which can be carried out as lift truck line,transfers the pallet with synchroneous movement below the body con-veyor, the lift truck elevates the components to enable the chassis and thebody to be fitted. With the help of a fitting facility (e.g. positioning pins) thecomponents can be correctly fitted taking into account a pre-defined tole-rance and assembly concept. The fitting can be carried out manually, semi-automatically or fully automatically. The fitting being successfully finished,the bolting process follows, most often fully automatical. The marriagecan be carried out in stop-and-go mode as well as in continuous flow.

50

The so-called "marriage" de-

scribes the fitting and bolting of

vehicle body with chassis inclu-

ding engine, brake system and

fuel tank. The pre-assembled

components are fed onto pallet

lift trucks, which are transferred

on an oval-shaped conveyor line.

the vehicle body and

is then automatically or semi-

automatically bolted.

Pallets

Fittingstations

There, the brake pipes, tank

pipes and the ABS cable tree and

other components are connec-

ted. Now, the pallet truck is con-

veyed below the vehicle body

and the pallet is raised. With the

help of a positioning system the

complete chassis with its com-

ponents is precisely fitted into

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Assembly EquipmentFASsemblyBody Chassis Marriage

Decoupling(manually,

automatically)

Bolting(manually,

automatically)

Manual backupfor fitting

(manually)

Fitting (manually,

fully or semi-automatically)

Front Axle Engine / GearboxUnit

Rear Axle Exhaust System,Drive Shaft, etc.

Marriage Area

Decking station

Bolting station

Your Advantage

Process-safe sequences

High availability

Minimum initial start period

Potential integration capacity of further vehicle types

Shortened project period and reduction of error cost by using 3D simulation tools

The Tasks

Elaboration of integrated overall conception by colla-boration with specialized departments of customer (planning, design, main-tenance, production)

Fitting of components into the body within continuous flow or stop-and-go mode

Bolting of components with body, manually or automatically

Peripheral prerequisites are to be taken into account (e.g. conveyor technology, tolerances of shell etc.)

Documentation of bolting data

Solutions for mixed vehicle operation (e.g. robot tech-nology)

52

Identification

Vehicle fixation

Wheel hub support

The wheel hub support consists of a support for the vehicle axles which is located on a floating plate and can be rotated horizontally. The floating plates guarantee that no tension is induced into the chassis.Moreover the wheel support grants a free translation and rotation of the wheel during the toe, respectively camber setting. There are various possibilities for the support of the wheel hub: wheel support with a pair of rollers with and without adapter disk, wheel support with hub gripping system, wheel support with supporting prism.

Wheel base adjustment

In order to realize an adaption of the machine to different wheel bases of various vehicles in mixed operation the axle setting systems are provided with a corresponding equipment. Therefore the wheel supports and the measurement units for the rear or front axles are displaced.

The vehicle fixation keeps the vehicle in a defined position which corresponds approximately with the symmetry axle of the axle settingsystem. In this way the vehicle is in fixed and steady position during the loading and setting.

The identification recognizes the vehicle and transmits all necessary vehicle data to the machine so that it can be set to suit the specimen. By means of the identification the desired setting values of the vehile geometry are transmitted to the setting system. There are 4 possiblities available: Manual entry, reading of a barcode on the vehicle, data carrier, calling up data from the host computer via the vehicle sequence.

53

Assembly EquipmentFASsemblySystem Elements Wheel Alignment in the Assembly Line

Documentation

In the documentation chassis geometry parameters before and after the setting are documented in connection with the vehicle identificationnumber. In addition to the storing of the values statistical evaluation is also possible.

Conveyor system

The conveyor system serves for the inward and outward transport of the vehicle. Therefore the hanger conveyor is used which is also applied for the marriage. The hanger conveyor has to support the weight of the vehicle and enables a fully automatic transport of the vehicle into the machine.

Axle setting system

The setting of toe respectively camber values on the vehicle can be rea-lized manually, semi-automatically or fully automatically. During the manualsetting the operator controls the related axle geomtry parameter by meansof a display which shows the difference between the acutal and the desired value. During the semi-automatic setting the operator adapts asetting tool which controls the the angle of toe respectively camber by theinput difference between desired and actual value. During the fully auto-matic setting the adaption of the setting tools also is realized automatically.

Axle geometry measurement

The axle geometry measurement system consists of measurement unitswhich will be located in front of all 4 wheels of the vehicle and whichacquire the axle geometry parameters. The measurement is realized bymechanical sensors or by a non-contact laser measurement system on ameasurement surface especially designed for this purpose. During the set-ting the axle geometry measurement system is able to acquire the angleof toe and camber on the rotating or stationary wheel. The axle geometrymeasurement system is calibrated by a master gauge which describesdefined angles of toe and camber close to zero.

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In this version the wheel align-

ment setting will be transfor-

med from the end of line to the

assembly line and precisely in

the unit assembly. The vehicle

is still in the overhead conveyor,

the wheels are still not assem-

bled. The wheel hubs can be

turned and the wheel suspen-

sion can compressed in a defi-

ned way. The wheel geometry

measurement can be executed

on the standing or turning

wheel hub.

Such type of test stands offer

good preconditions for full auto-

matic sequences. The use of

robots offer additional advan-

tages. The hall planning will be

eased, pits are not necessary.

The quantity of the equipment

necessary at the end of line will

be reduced and there is more

time for extensive testing

scopes.

Your Advantage

Simple hall planning

No pits for wheel alignmentnecessary

Use of existingtransport systems

Optimal execution of the measurement surface

Feeler mechanical or without contact with laser

No influence because of different wheels and tires

Adjustment after marriage; body in white tolerances have no influence on the adjustment

Good accessibility of the setting points, as no wheel yet assembled

Flexible automatic adjust-ment sequences with robots can be realized

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Assembly EquipmentFASsemblyWheel Alignmentin the Assembly Line

With the new developed hub

clamping device considerable

advantages will be given in the

axle adjustment station as well

as in the wheel alignment adjust-

ment in the line. The system

holds the wheel hub and esta-

blishes a safe mechanical con-

nection.

At the wheel alignment in the

line it is advisable to realize the

adjustment of toe fully auto-

matic. The device can be desig-

ned process optimized, the set-

ting time will be reduced. There

must not be considered any

restrictions and border con-

ditions, as they exist for reasons

of the ergonomics in the wor-

ker operation.

Through the not yet assembled

wheel the setting points are

better accessible for automatic

tools. By using robots these test

stands have a high flexibility.

This also appears in the life

cycle costs, e.g. when a model

change is in view or when seve-

ral vehicle types are adjusted on

the same test stand.

Your Advantage

No necessity of adapter disks

Fully automatic adaptionat the wheel carrier

No work for assembly/disas-sembly, storing and transpor-tation of the adapter disks

No influence on the pre-cision by damage of the measurement surfaces, as it could appear withadapter disks in the rough use

Your Advantage

No overhead work for the worker

High flexibility through simple adap-tation to different vehicle types

Worker independentprocess

Shorter adjustment time

between hub and test device.

The wheel suspension can be

compressed in a defined way.

Moreover, the hub can be tur-

ned over the hub clamping devi-

ce during the wheel geometry

measurement. The measure-

ment areas lie secure in the

test stand and can be scanned

mechanically as well as without

contact by laser. The use of

adapter disks with all their dis-

advantages is no longer neces-

sary. With this the hub clamping

device offers all preconditions

for full automatic sequences.

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Other Versions on Request

Technical Specifications

Size /Working Range /Lift Working Range in mm Lift in mm

800 820-1740 920

Weight

Capacity 25 KN max.

Off-centered Load in x-y 1 KN max.

Retrackting Force Natural weight and load

Speed

Max. Lifting Speed 120mm/s

Temperature

Ambient Temperature0° C to +40° C

Operation

Cycle Time 4 min / cycles, 1x double stroke (1x extension and 1x retraction)

Number of Shifts 2-3

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The Application

The lifting device enables different installations as mentioned below:

Stationary - without a changeof the place of installation

Mobile - for an easy change of the place of installation

Movable – on a vehicle for horizontal movement by own drive

Our lifting device is used for

heavy lifts mainly in the assembly

area. Picked up loads can be

moved throughout the entire

area by own mechanism. The

lifting device has a compact

design and high carrying capa-

city. Lifted components can be

guided and joined according to

preset speed / travel diagrams.

Two lifting devices may be

installed to enable higher loads.

Arrangement is possible in

many different ways depending

on the location of the load and

the required accessibility.

The lifting devices are intercon-

nected via the mechanical drive

or by electric control.

System Elements

Lifting DeviceMain Components of theLifting Device:

Support

Lifting spindle with trape-zoidal thread or ball screw

Lifting Mechanism I & II

Chain System

Linear Guide

Drive

Motor

Drive Shaft

Control

Electro-mechanical push-buttons are integrated into the lifting device. Other control elements are con-tained in the system.

Your Advantage

Minimum height

Compact design

High stiffness for insus-ceptibility to off-centered loads and thus a high joining accuracy and a long service life

Use of proven mechanical components

Little installation expense

Excellent maintenance and repair possibilities

Controlled lifting speed throughout the entire working range

Assembly EquipmentFASsemblyLifting Device

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In the field of vehicle finalassembly the modules to be fitted to the vehicle becomemore complex. For the neces-sary assembly processes, suchas screwing, gluing, handlingand testing, mechanisationsolutions are needed to reliablyexecute those processes,whether partly or fully automatic.FA

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Installation facilities for the assembly of vehicle modules,e.g. cockpits, front-end mo-dules, tanks, etc..

Combinations of various pro-cesses like gluing, assem-bling, adjusting and testing are possible

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Assembly EquipmentFASsemblyModule Installation

Tank installation manipulator

Computer-aided design of tools, e.g. for fronted

Robot operated VIN marking of car bodies

Cockpit installation device

Manipulator for front-end installation

Automatic installation ofa spare wheel trough (incl.adhesive application)

The Application

Modules:

Cockpit installation

Front-end installation

Tank installation

Assembly of Cw-subfloor,roof interior/DVD

Installation of spare-wheeltrough

Marking of vehicle identifi-cation number (VIN)

Types and automationlevels:

Manually operated installation tools

Partly automatic installation facilities, manipulators

Robot-operated tools

Integrated and combi-nable processes, e.g.:

Gluing, screwing

Marking, stamping

Testing, adjusting

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Robot-controlled installation tool for glass roof module

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The Aplication

Automatic installation of glass roofs through robot controlled installation tool

Flexible integration of diffe-rent component suppliers for e.g. robots, measuring systems and adhesiveapplication

High installation accuracy through mechanical guidanceof the glass roofs instead of costlier contactless measu-ring technique

Concept layoutMechanically centred installation at the vehicle via robot

Automatic feed of glass roof modules

6-axes industrial robot Adhesive application unit

Vacuum grippers Receiving and centring facility

3D-camera system / laser technology

Central control

• Exact installation of window in the car body

• Administration of the pro-cess, signal handling between components

• Handling of different window sizes

• Window reception, centring, type recognition, measure-ment

• With nozzle at the 7th robot axis, supply of adhesive with required pressure and con-stant temperature

• Three-dimensional motions, “teaching”

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Assembly EquipmentFASsemblyGlazing

The Function

Installation of front, rear and side windows• 6-axes robot makes

adaption to other glass types possible by “teaching” of sequences

Reliable adhesive application• Dispensing of the adhe-

sive at constant tempe-rature and pressure

• Adhesive application nozzle is velocity-depen-dent controlled by the robot as its 7th axis

Positioning accuracy• Centring facility• 3D-image processing or

laser technology

Monitoring and central control of process• Possibility for connec -

tion to higher-level con-trol systems

Various levels of automa-tion

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Beside complex filling systems

Dürr Somac provides turnkey

solutions for the filling, testing

and marking of vehicle compo-

nents.

The scope of services includes

early advising of our customers,

the use of own testing facilities

as well as specification and

design of the optimum solution,

manufacture and assembly,

commissioning of the equip-

ment at the customer’s site and

last but not least a worldwide

service network of the Dürr

group.

Markingunit

Optical testing station

Parts feeding

Sealing station

Oil filling stations

Fully automatic assembly line for shock absorber systems

Automatic assembly and testing stationfor vehicle brake and clutch cables

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Assembly EquipmentFASsemblyFilling, Testing and Assembly of Vehicle Components

The Tasks

Fields of application for

combined assembly, filling

and testing processes:

Assembly and leak test of brake and clutch cables

Oil filling of engines, gearboxes and gearbox components

Component filling of clutch and brake systems

Full-automated oil filling of shock absorber systems and assembly of damper struts

Pre-filling of power steering systems (powerpack)

Equipment for leak testing of components

Fully automaticassembly line for

shock absorbersystems

Filling of gearboxes

Pressure testequipment forcondensers andevaporators

Oil filling stationfor automaticgearbox converter

Oil filling equipmentfor shock absor-ber / power packs

Assembly andtesting of clutch

cables

Assembly ofshock absorber

and mountedparts to complete

damper struts

Filling and testingequipment forclutch master

cylinder