Assembly line for the EGR valve - Audi V6

Semi-automated production line of our own design for assembling the 3rd generation Audi EGR valve with subsequent adaptation for the alternative assembly of the 2nd generation EGR valve.

Assembly line for the EGR valve – Audi V6

Name of contract: Development and delivery of an assembly line for the Audi V6 EGR valve
Term of delivery: 2015-2016

SPECIFICATION:
The project was launched at the customer´s inquiry for automated production of the EGR valve for a new generation of Audi cars. The specification was finalized at subsequent technical meetings, and a decision was reached to construct the line out of individual operator-manned stations. During the line´s construction, the project was expanded to include modifications to enable the lines to produce the previous generation of EGR valves.

SOLUTION – PARAMETERS:
Line cycle: 60 sec / pc
Capacity: 350-400 valves / shift

THE LINE CONSISTS OF A TOTAL OF 9 SEPARATE MACHINES THAT PROVIDE FOR THE AUTOMATION OF THE ENTIRE PRODUCTION PROCESS:

MACHINE 1: V-seal cartridge assembly – complete automation of the cassette assembly process from 4 separate parts. MORE HERE

MACHINE 2: Pressing the bushing and V-seal cartridge into the valve housing – the operator puts the parts into the jigs. The machine does the automatic pressing and crimping of both parts into the valve housing at six workplaces. MORE HERE

MACHINE 3: Assembling the roller and pressing the pinion into the DC-motor – complete automation of the workstation for assembling the roller (with roller bush). The operator likewise oversees the operation of the semi-automatic workstation where the pinion is pressed into the DC-motor. MORE HERE

MACHINE 4: Completing of the EGR valve stem sub-assembly – automation of completion of the stem sub-assembly, which is done under an operator´s supervision at 12 workstations within one machine. MORE HERE

MACHINE 5: Assembling the ball bearing into the mounting sheet and pressing the spring and gear wheel assembly – cleaning and welding the ball bearing to the mounting sheet and the automation of the process of pressing the spring and gear wheel assembly into the welded ball bearing after assembly by the operator. MORE HERE

MACHINE 6: Pressing the screw and laser welding of the bearing bracket – workstation automation with one operator for pressing the screw onto the gear shaft and complete automation of the workstation for assembling the bearing bracket and laser welding it to the mounting sheet. MORE HERE

MACHINE 7: Lubricating the screw and assembling the valve housing, internal components and valve mounting sheet – the operator puts the individual components into the equipment, which then automatically screws the parts into the nearly complete valve unit. MORE HERE

MACHINE 8: Welding the stainless steel poppet and assembling the valve housing – automation of welding the stainless steel poppet to the wheel assembly and aligning the valve housing. MORE HERE

MACHINE 9: Testing the tightness and operation of the valve – the operator performs the manual installation of the finished valve, all testing activities and the in-jet marking of the valve is entirely automated. MORE HERE

BASIC CHARACTERISTICS:

Automated line of TEMEX design
COGNEX + KEYENCE vision systems
COGNEX DMC code readers
Part manipulators of TEMEX design
ROX vibrating input feeders
TOX servo presses
ATEQ air testers
FESTO vacuum and pneumatic technology
Electric screwdrivers with fully automatic feeding of screws of our TEMEX production + DESOUTTER screwdrivers
KEYENCE analogue measuring systems
FESTO electric servo axles
RAVEO servo drives
HBM load cells for force measurements
MEATEST torque measurements
Laser welding with TRUMPF source using PFO 2D TRUMPF head
WEISS/STASTO 6-position and 12-position rotary table
EOL valve test and programming it using EMTRONICS and MELEXIS technology
HW – SIEMENS SIMATIC S7
The housing of our design from ITEM Al profiles