Machine No.7 – worm lubrication and pre-assembly of the EGR valve body

Machine with two workstations for worm lubrication and pre-assembly of the EGR valve housing

Project: Assembly line for the EGR valve – Audi V6 
Number of workstations within the machine: 2
Term of delivery: 2015 – 2016

PARAMETERS:
Width: 1600 mm
Depth: 1500 mm
Height: 2600 mm
Weight: 900 kg
Operating pressure: 0.6 MPa
 

FEATURES:

The machine is a crucial component of the line in terms of incorporating individual internal parts into the housing of the EGR valve.
The machine´s job and its workstations are to lubricate the worm in the mounting sheet subassembly automatically, but especially the assembly and attachment of internal parts of the valve body, including positioning the DC-motor with pinion, valve stem subassembly and mounting sheet with gear wheel subassembly.
 

DESCRIPTION OF THE WORKSTATIONS:

DT1 workstation
The DT1 workstation assembles the valve housing and all internal components. Following the workflow, the operator inserts the individual subassemblies of the DC-motor with pinion, valve stem assembly, and mounting sheet assembly into the housing. The machine then automatically completes the assembly of the valve´s internal parts by screwing the mounting sheet into the valve housing.
Control system feedback: camera check of the presence of individual components during assembly

DT2 workstation
The DT2 provides supports the assembly of internal components of the valve housing at the DT1 workstation. The operator places the subassembly of the valve mounting sheet into the fixing jig, after which the workstation automatically extends the lubricating head and lubricates the threads of the worm. The operator then takes the subassembly with a lubricated worm and uses it to complete the valve housing at the DT1 workstation.
Feedback: check to ensure the proper amount of grease is applied to the helix

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

Parts of the machine (front side):
a) Control unit for the Desoutter screwdriver
c) DT1 workstation: Assembling the valve housing
d) Control box with buttons for the DT1 workstation
f) RM1 electrical switchboard
h) OP panel
j) DT2 workstation: Lubricating the worm
l) Control box with buttons for the DT2 workstation

Parts of the machine (rear side):
a) Vibrating feeder for screws with a vibrating bar
b) Rear door for access to the DT2 workstation
c) RM1 electrical switchboard

DESIGN OF THE MACHINE:

• Robust steel frame with closed rails for ease of handling with a forklift,
• Solid/polycarbonate panels – as fixed surfaces or as doors,
• Workspaces are secured with optical security barriers, electric security locks, or bolted connections,
• Control buttons within easy reach of the operator, the operator panel and monitor for watching the results of the assembly at the DT1 workstation above the DT2 workstation,
• Electrical switch port in the rear part of the machine, the same as the hopper with screws and vibrating feeder,
• Connecting the machine to the work area exhaust system.