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Case Studies

Hydraulic Press Valve Relief 

Valve manufacturers today are able to inspect parts during assembly rather than after to produce near-perfect fluid pressure relief valves. The Promess Electro-Mechanical Assembly Press (EMAP) uses no pneumatics or hydraulics; instead, press motion is initiated by a servomotor and ball screw.

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Steering Knuckle Bushing Press with EMAP

Assembly of bushing into the right and left steering knuckles that are being used today in the automobile industry. Challenge: Initially this process was performed using a hydraulic press. The specification calls fora total tolerance of +0.5mm on the position of the bushing relative to a datum point on the casting. This tolerance must be held despite the fact that the steering knuckle castings vary in thickness. Without any closed-loop feedback, this tolerance could not be held using hydraulics.

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Power Steering Pump Assembly with EMAP

On a power steering pump, the pulley must be assembled onto the pump shaft relative to a machined surface on the pump housing. The pulley needs to be assembled onto the pump shaft relative to three mounting flanges located on the pump housing, it cannot be pressed onto the shaft and the machine must be able to assemble different models of pumps with quick change over.

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Water Pump Assembly with EMAP

In the assembly and manufacturing of automotive water pumps, there are various components that need to be pressed to a dimension relative to a machined surface on the pump housing and not to a shoulder. This is important for proper pump flow and belt alignment. These assemblies include the bearing pack,the impeller and the hub.

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Backlash Testing

Measuring backlash is a critical test in almost all cases of gear manufacturing. A backlash specification is the criteria for how “loose” or “tight” a gear set is. Examples of too tight of backlash can create a jamming scenario under thermal expansion of the gears. Too loose backlash can result in the gears interfacing on a weaker part of the gear teeth.

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Automotive Seat Recliner Mechanism with Torque

Testing seat recliner mechanisms to verify they meet all customer functionality and government safety critical requirements. The Promess TorquePRO supports full functionality testing of the seat recliner measuring torque, rotation and angle, return spring force, latch/unlatch effort, tooth engagement (proof loading), and tooth backlash (chuck), while controlling the rotational motion of the assembly.

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Bearing Preload Test with TorquePRO

In the manufacturing of precision bearings, every bearing must go through a final quality test where the breakaway torque and the running torque are measured to determine the bearing preload. The bearing preload is determined by measuring the torque required to rotate the inner race while the outer race is held. Every bearing manufactured is tested before it is shipped to the customer.

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Assembling Automotive Belt Tensioners with Promess REMAP

Producing automotive belt tensioners requires an assembly system that can monitor and control both linear and rotational motions in real-time to achieve the proper assembly sequence. The tensioner consists of a spring inside a housing which must be wound either to a specified location or to a specified torque. Once the spring is positioned inside the housing the linear actuator presses everything together with a controlled force that is light enough to allow the spring to turn while still being sufficient to hold the assembly together. At that point, the rotary axis is actuated to wind the spring to the specified position or torque, depending on the model being assembled.

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Composite Compression

The most common assembly process for composite parts is compression molding. Material is inserted between coordinated metal dies and then pressed together under a high amount of force. The customer was previously using hydraulic presses and running into issues with inconsistent parts. The customer needed to be able to monitor the force and position throughout the process, while regulating the speed until the desired programmed force is reach. Then this force must be maintained for a specified time.

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