classic | mobile
 

Search...

 

Customised stud press
2nd Quarter 2017, Shaft power components


Tectra Automation successfully designed and fabricated a tailor-made stud press for use in manufacturing components for Ford’s Ford Ranger and Ford Everest vehicle ranges. Commissioned for the project by Auto Industrial, the provider of machining and assembly of various automotive components, the stud press is used to insert the wheel studs into the front and rear hubs for these two vehicle types. With no standard stud press on the market that could meet the customer’s requirements, Tectra Automation was approached to provide the solution.

Beginning with the concept in 2015, several design changes to this industry first saw the stud press evolve to a servo-mechanical system before the official order was received in July 2016. The brief was to design and build a press that could insert the wheel studs into the front and rear wheel hubs in the specified vehicle types, both of which are built in South Africa.

The stud press is required to press-in each stud effortlessly using a maximum of 56 kN force and it must also record an accurate data capture of each press in cycle while providing a production rate of 175 000 hubs per annum. In addition, Auto Industrial requested that the press be able to assemble at least two studs at once while controlling the force and distance travelled accurately, and the specifications required tight tolerances after assembly. Furthermore, the press was required to perform an infrequent press-out test as part of the quality assurance process.

To achieve these requirements, Tectra Automation designed and manufactured the stud press frame from the Rexroth range of basic mechanical elements. “The studs are pressed in using two Rexroth EMC100XC actuators each driven by a Rexroth MSK060C motor through standard 20:1 GTM100 gearboxes,” explains Kevin Lombard, general manager, Tectra Automation. “A turntable to rotate the hub is driven by an MSK040C motor through a 20:1 GTE80 gearbox and control is provided by a Rexroth CML25.1 PLC. Control for the HMI front-end with onboard PC is enabled by the IndraControl VEP 40.5. Additionally, we used customised load cells to measure the exact force and we designed the program to operate and record the data inhouse.”

Tectra Automation’s ingenuity was brought to the fore as its engineers designed a special motor attachment to enable smaller motors. This was necessary as the two EMC 100XC electromechanical cylinders had to be placed exactly on the pitch circle diameter of the bolts in order to limit any abnormal shaft loading. “To provide the torque required to generate 56 kN force,” Lombard elaborates, “we used 20:1 double reduction planetary gearboxes attached directly to the motors.” Additional sensors to detect any possibility of a faulty hub passing through were required and Tectra Automation was also responsible for the data capturing system related to each press in operation. The data is downloaded on to Auto Industrial’s network for storage purposes.

“A real benefit to Auto Industrial is that by incorporating product monitoring during the press-in phase, the company can guarantee product quality without the need for additional production monitoring steps,” Lombard says. “If at any stage the program determines that the press-in process deviates from the specification, the press will stop and the operator will have to call a supervisor in order to reset the operation. The faulty part is removed and set aside for examination, thus minimising the possibility of faulty parts going through the system.”

The project was completed and commissioned during July and August 2016 at Tectra Automation’s premises, where the factory acceptance hubs for testing by Ford are assembled. All work was completed within the specified time and the stud press was delivered and installed in January 2017, with an accompanying 12 month guarantee in place.

“The success of this project, and all projects we do, is based on the extensive range of products we represent within the Hytec group of companies. It enables us to design and build fairly complex systems at relatively low costs using in-house expertise related to the individual product ranges,” says Lombard in conclusion.

For more information contact Kevin Lombard, Tectra Automation, +27 (0)11 974 9400, kevin.lombard@tectra.co.za, www.hytecgroup.co.za


Credit(s)
Supplied By: Tectra Automation
Tel: +27 11 971 9400
Fax: +27 11 971 9440
Email: sales@tectra.co.za
www: www.hytecgroup.co.za
Share via email     Print this page  

Further reading:

  • Quick-Flex drive couplings
    4th Quarter 2017, Bearing Man Group t/a BMG, Shaft power components
    BMG’s Timken Quick-Flex couplings are designed to transmit torque from a driving shaft to a driven shaft and to accommodate shaft misalignment within the drive. These maintenance-free couplings also dampen ...
  • New easy-to-use valve series
    4th Quarter 2017, Tectra Automation, Pneumatic systems & components
    Tectra Automation has brought the Aventics ES05 Essential Valve System series to South Africa. The ES05 series now offers a clever, economic and user-friendly solution for applications with standard requirements ...
  • Bearings and housings from KML
    4th Quarter 2017, Shaft power components
    Bearings International (BI) offers a range of mounted and unmounted bearings and bearing housings from KML Bearings, as well as automotive-specific products for the passenger and commercial vehicle sectors. ...
  • Megadyne expands its range
    4th Quarter 2017, Megadyne SA, Shaft power components
    The Megalinear Quiet Self Track (QST) polyurethane self-tracking, silent running timing belts are specifically designed and manufactured to reduce the noise level generated during high speed operation. ...
  • Bearing innovation for Formula 1
    4th Quarter 2017, SKF South Africa, Shaft power components
    In Formula 1, weight, friction and unexpected failures are enemies of high performance, and every detail matters. With a long history of providing superior solutions to aid superior performance, SKF’s ...
  • Low noise conveyor system with fast assembly
    4th Quarter 2017, Tectra Automation, Other technologies
    Future-proof production, assembly, and packaging lines must be able to deal with even smaller batches, more frequent product changes, and a large number of product variants. Chain conveyor systems used ...
  • Precision balancing of rotors
    3rd Quarter 2017, Shaft power components
    As the operator of the largest independent high-speed dynamic balancing machine in sub-Saharan Africa, Marthinusen & Coutts has an in-depth understanding of the importance of precision-balancing rotating ...
  • High performance electrically insulated bearings
    3rd Quarter 2017, SKF South Africa, Shaft power components
    With its latest generation of electrically insulated bearings, SKF has raised the performance standard to provide constant electrical performance, even in high humidity. The Insocoat bearing range comprises ...
  • Gear units need no adaptors
    3rd Quarter 2017, Stone-Stamcor, Shaft power components
    The full range of Hydromec gear units is available from Stone-Stamcor. Manufactured in Italy to European quality standards, the Hydromec range comprises worm, helical, helical-bevel, parallel shaft gear ...
  • Tin spraying system for baking plant
    3rd Quarter 2017, Tectra Automation, Electrical switching & drive systems & components
    Tectra Automation recently designed and supplied the Tectra 650 automatic tin spraying system to Bakesure Ingredient Suppliers, Africa’s leading baking ingredients and solutions provider. Bakesure required ...
  • BMG services the sugar industry
    3rd Quarter 2017, Bearing Man Group t/a BMG, Shaft power components
    BMG’s KZN field service team has been involved in a number of field service projects in the local sugar industry during recent off-crop seasons, as well as dealing with urgent breakdowns in sugar mills ...
  • Heavy industrial couplings for arduous applications
    3rd Quarter 2017, Bearing Man Group t/a BMG, Shaft power components
    “BMG’s Falk Steelflex couplings have also been proven to minimise downtime – an important factor in determining the total cost of ownership,” says Carlo Beukes, general manager, power transmission. “Couplings ...

 
 
         
Contact:
Technews Publishing (Pty) Ltd
1st Floor, Stabilitas House
265 Kent Ave, Randburg, 2194
South Africa
Publications by Technews
Dataweek Electronics & Communications Technology
Electronic Buyers Guide (EBG)

Hi-Tech Security Solutions
Hi-Tech Security Business Directory

Motion Control in Southern Africa
Motion Control Buyers’ Guide (MCBG)

South African Instrumentation & Control
South African Instrumentation & Control Buyers’ Guide (IBG)
Other
Terms & conditions of use, including privacy policy
PAIA Manual





 

         
    classic | mobile

Copyright © Technews Publishing (Pty) Ltd. All rights reserved.