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TRANSCRIPT
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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
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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
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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
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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.
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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
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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
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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.
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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
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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.
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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.
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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)
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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.
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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