|
|
Upcoming SMAC Shows and Events
Semicon Japan
12/3 - 12/5
Makuhari Messe, Japan
|
|
|
SMAC - Automotive Applications
Automotive Applications
Automotive industry parts and assembly quality standards have moved from sigma level sampling to zero defect requirements. These more stringent manufacturing results can be achieved through a combination of containment through 100% inspections (eliminating bad parts) and correction through immediate feedback and adjustment. Inspection by hand can be reduced or eliminated, parts rejection can virtually be eliminated, and tool wear can be substantially reduced, all while increasing the pace of production.
Screw Thread Checking
The requirement for strict specification and acceptance of all automotive parts and components has greatly increased in recent years. Screw thread inspection is no exception. The common practice of eddy current probes, lasers, proximity sensors or vision systems are only partly successful as they only inform you of the presence of a thread, not if it's correct or within tolerance. The unique low-cost SMAC solution enables you to automatically check the following screw thread parameters:
- Oversize or undersized threads
- Cross threads
- Thread depth
- No threads
- Mis-located threads
- Thread pitch
- Shallow or blocked hole
The automated thread checking solution from SMAC enables a 100% detailed inspection and verification of all parts. It also identifies tool wear sooner, and allows SPC data acquisition for process control and quality systems. All of this translates to higher quality and throughput, lower costs and increased customer confidence.
Oil Pan Thread Checking
Oil pan threads were checked using a plug thread gauge coupled directly to the end of the shaft of the SMAC actuator.
Wheel Bearing Casting
The system checked for shallow tap, undersize or oversize threads and chamfer depth.
Fuel Valve
Five SMAC LAR55s were used to check threads and adjust valve flow rate at the same time.
Similar Applications
- Water pump casting
- Cam shaft
- Steering housing casting
- Axles and axle covers
- Fuel injector nozzle
Seatbelt Buckle Testing
Requirement: Perform a sequence of tests on a seatbelt buckle assembly to ensure correct operation of the latching and release mechanisms.
Test 1
Insert seatbelt clasp into buckle ensuring that it latches and register position and forces required. This test was performed in the following sequence:
- Rapid move to position.
- Step forward 0.25mm, wait for unit to settle, display holding force.
- If unit has reached "latching position," retract to home position, else jump back to step 2.
- The test is repeated five times on each assembly to show repeatability.
Conclusions: The latching mechanism was always seen to be less than the 30N force required, mostly being around the SQ9000-SQ10000 (12.6 – 14N) level. This is quite easy to detect with the actuator.
Test 2
Depress release button and register position and forces at the point of release. This test was performed in the following sequence:
- Rapid move to position.
- Soft-land on button.
- Apply force, check position. If position is greater than "X" (x = release point), jump to step 4, else increase force by SQ1 (15 gram approx) and repeat.
- Display maximum force, retract to home position.
Conclusions: The release force was always repeatable at around the 12N level. Again, this was well within the range of the LAL90. The second buckle was slightly less repeatable but always in the range SQ86 – SQ91 (11.7 – 12.3 N).
Test 3
Same as Test 2 but with a 300N load being applied to the clasp. Determine position and forces of release. With the setup, used it was not possible to apply a force of 300N to check release force. However, a small force was applied to the buckle and a corresponding increase in force was observed. This test may have to be proven on site.
It was recommended that the LAL95-050-75 F be used for the latching test and LAL95-015-75 F for the pushbutton test. Using two actuators would require only one setup for the test. It was recommended that the 300N tension force should be applied by a pneumatic cylinder while the SMAC unit carries out the button test.
Automotive Switch Testing
The benefits of incorporating SMAC actuators into switch testing applications include:
- Linear/Rotary and XYZ systems allow buttons to be tested sequentially
- Compact size, light weight and built-in measuring capability facilitate integration into production line stations
- Life tests can be carried out automatically
- Tests are performed with outstanding levels of accuracy, velocity and repeatability
- Force/Position/Time charts can be easily generated
- Rotary switch positions and torque are accurately gauged
- Slight torque value differences can be detected
Common Applications
- Horn switches
- Car stereo buttons and knobs
- Mechanical latches
- Electric window rocker switches
- Multi-function switches
- Micro-switches
- Membrane keypads
- Combined linear and rotary moves for key locks
- Safety relays
Typical Testing Sequence
- Touch the surface with as little force as needed
- Learn the initial position
- Push all the way down and determine click point and extreme position
- Measure minimum force needed to activate the switch
- Pull up and measure the force
- Check whether the initial position has been restored
- Report on all acquired data
- Generate force vs. position graphs
All these steps can be performed and the data captured in very short cycle times.
Fuel Injector Component Quality Control
Problem: Customer was experiencing problems with lasers, including inconsistency, lack of reliability and insufficient repeatability, and no gauge correlation to the offline manually operated master gauge. The parts were hand sorted with a manual gauge using a dial indicator.
Solution: SMAC automated the manual gauging process. A linear actuator with 0.1um resolution encoder replaced the dial indicator, which provided a very repeatable motion profile. The SMAC solution was 40% better than their best manual gauging repeatability and reproducibility study.
Fuel Injector Plug Gauging
The bore inside a fuel injector part is in a deep-drawn metal part inside of a plastic injection molded body. Sometimes during the injection molding process, the bore is crushed. Gauging, performed by LVDTs, load cells and air cylinders, left marks on the fuel injector plugs being measured, causing all of them to be rejected by the end customer, a major automobile company. The parts manufacturer turned to SMAC for a solution.
Gauging is now done with a plug gauge on the end of an LAL20-25 (with a maximum of 100 grams force) to detect if the hole is undersized, crushed or dented in, without marking the part during the process. The customer states that with the SMAC technology applied, that they are able to detect obstructions in the bore as small as five to 10 microns.
Key Operational Details
- 100% in-process inspection
- The contoured probe performs a soft landing to engage the inside wall without damaging or deforming the surface
SMAC Advantages
- Delicate touch means that contact surfaces can still be measured even if they have different shapes, texture or compressibility
- Data Acquisition capability
- Soft-Land prevents marking or damage
- Controlled force ensures consistent measurement
- Repeatability
|
