2nd Quarter 2018Electrical switching & drive systems & components
Tectra Automation designed, manufactured and commissioned a servo-driven automotive press for Auto Industrial (AI). The application-specific press is used by AI to assemble various front suspension linkages for a local range of light commercial vehicles in such a way that it produces one part every 40 seconds for 22 hours a day.
Tectra Automation was responsible for every aspect of the press aside from the tooling, which was manufactured in-house by the client. To facilitate the production of one part every 40 seconds, a Rexroth L25 motion PLC was used with control provided by a Rexroth VEP40 HMIK with on-board PC. Tectra Automation designed and manufactured the control panel as well as the operation software. The Rexroth EMC-125-HD electromechanical cylinder, driven by an MSK101D servo motor, was selected for control instead of using a hydraulic cylinder due to its cleanliness, high degree of controllability and operational quietness.
“The press has an integrated load cell to control and record the press-in force in order to guarantee consistent quality,” explains general manager, Kevin Lombard. “The ram is guided by Rexroth heavy duty linear bushes running on hardened and ground linear shafts. The rotary table is driven by a Rexroth MSK050C servo motor driving a GTM planetary in-line gearbox. By utilising various sensors, the program will alert a supervisor in the event of an operator error. Any parts not conforming to the required press-in force specification will require intervention to ensure that no rejects pass through the system.”
The mechanical structure was subcontracted to longstanding Tectra Automation customer, Machine Tool Promotions, (MTP) and assembled on its premises. From here, final assembly and testing took place at Tectra Automation’s facility and the press was subsequently delivered to the client. Project duration was only four months and commissioning took place onsite over a fortnight. The first week of operation was dedicated to on-the-job operator training and technical training for maintenance and supervisory staff was conducted simultaneously.
“We kept Auto Industrial constantly informed of the project status and liaised with them regarding proposed changes and additional features,” Lombard concludes. “They appreciated this professional approach and we were subsequently commissioned to engineer a customised wheel stud press for another of their local automotive clients.”
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