How to Achieve 100% In-Process Verification in Your Press Fit Operation
Too many manufacturers rely solely on statistical testing to verify product quality; at best they test random samples and assume that if their samples are all in spec, then everything else should be too. Some manufacturers may even have more robust end-of-line inspection, and while that may be a bit more reliable, it only catches a problem after the part has been poorly produced and usually results in higher rates of scrap.
If there was a way you could easily and reliably test for product quality, in-process, before the component ever left the assembly station, and where the problem could still be rectified without having to scrap the part, you’d do it, right?
And if there was a way to achieve 100% in-process quality verification, you’d certainly jump all over that.
Well, with a little bit of today’s manufacturing technology, along with some innovative engineering, not only is it possible, it’s being done already by many of the most successful and prominent manufacturers in the world today.
Let’s take a look at a simple press-fit operation and how it might be done with an Electro-Mechanical Assembly Press (EMAP) system:
1. Parts are loaded into the fixture (in this case, a bushing being pressed into a bore). From prior testing, it has been determined that a good press-fit occurs with 12kN of force and is properly positioned when the bushing has been moved 25mm past the touchpoint, but not so far that it has bottomed out.
2. Operator inputs, part-present sensors or any of several other devices may be used to initiate the process.
3. Once the process is initiated, the ram of the EMAP extends at a fully-programmable, appropriate speed until it makes contact with the part. This “touchpoint” is recognized by the system’s built-in force transducer.
4. The Promess Electro-Mechanical Press then continues to press the bushing to a location 25mm from this touchpoint, and the ram retracts, having captured both the final position AND the force, throughout the work that has been done.
5. The data captured is graphed, displayed and gaged against a known or “taught” ideal part, +/- the amount of variance you have determined is acceptable, and that assembly is assigned pass or fail status.
This process, using an EMAP press, produces results that are 100% verified, in process, before your
assembly ever leaves the station. You are supplied with immediate data on the process, that gives you the power to decide, intelligently, how to best proceed.
With today’s technology and innovation, backed by support available 24/7/365, there is a way to achieve 100% in-process quality verification. There is a way to ensure every assembly you produce meets or exceeds your customers’ expectations and there is a way this can be achieved with minimal scrap and/or waste.
It is often said that knowledge is power, and with the data produced by a Promess system as it delivers accurate and repeatable, programmable force, position & torque, you have the power to supply your customers with the best products, consistently and reliably.
The real question is not merely how to achieve 100% in-process quality verification; we’ve got that figured out already.
The real question is, if 100% in-process quality verification could help you more consistently achieve higher quality, why aren’t you doing it already?