Productive without Compromises

Oil pump assembly line incorporates the following processes:

• Oil pump housing and cover are manually loaded onto the work piece pallet and transported by automation to the individual assembly operations
• Automatically load and press-in of adapter sleeve
• Automatically load and assembly of ball and spring with function check
• Assembly of drive shaft and directional flow control valve in separate pre-assembly station
• Automatic load and assembly of drive shaft and control unit in proper orientation into the pump housing
• Automatic load and assembly of control piston with pressure spring into pump assembly
• Automatic bolt feed and assembly of oil pump housing with cover plate
• Orientate drive shaft and check free movement of the oil pump unit
• Automatic load of sprocket
• Automatic bolt feed and assembly of sprocket with drive shaft
• Automatic load intake
• Automatic bolt feed and assembly of intake with pump
• Manual unload of oil pump and load into the work piece specific, transport dunnage

Assembly line for the assembly of the balance shaft housing with integrated oil pump incorporates the following processes:

• Balance shaft housing and oil pump covers are manually loaded onto the work piece pallet and transported by automation to the individual assembly stations
• Manually load and automatically assemble/press-in adapter sleeves, seal cap, seal ring and control piston (including spring)
• Automatic load and press-in of ball with subsequent leakage test
• Manually load ball including spring plus seal cap and insert into pump cover with subsequent function test
• Manually load drive shaft and external rotor into oil pump plus gasket into intake manifold
• Manual insertion of bolts and automatic assembly of balance shaft housing with cover
• Orientate drive shaft and check functionality of control unit
• Manually assemble sprocket with drive shaft, balance shaft to the housing and sprocket to balance weight
• Automatic tightening of sprocket to drive shaft plus sprocket to balance shaft
• Automatic inspection of sprocket run-out, oil pump pressure as well as friction loss on drive shaft and balance shaft
• Automatic unload of balance shaft housing and load into the work piece specific, transport dunnage

Camshaft carrier module assembly line incorporates the following processes:

• Camshaft carrier and camshafts are loaded manually onto the work piece pallet and transported by automation to the individual assembly stations
• Automatic unbolting and removal of cam caps
• Automatic transfer of camshafts from pallet to camshaft carrier
• Automatic tightening of cam caps with camshafts in carrier module – quality data for each bolt tightening operation is captured and recorded
• Automatic torque to turn inspection, quality date is captured and recorded
• Automatic robot unload of camshaft carrier module in head assembly line

Assembly line for the assembly of the airbag incorporates the following processes:

• Airbag housings are manually placed onto fixture and clamped in the assembly station
• All components are manually assembled to the airbag housing
• Fully automatic tightening of the components in separate assembly station
• For each bolt tightening operation, the torque and angle quality data is captured and recorded
• The assembled airbag is manually unloaded and loaded into the work piece specific, transport dunnage

Assembly line for the assembly of cylinder heads incorporates the following processes:

• Cylinder heads are moved manually on work piece carriers on a conveyor system
• Manual removal of the cam cap
• Manually press on valve stem seal
• Manually insert valves
• Manually insert lower spring plate, valve spring and top spring plate
• Manually assemble split retaining wedge onto valves stem at manual wedge station
• Insert master valve clearance shim, pre-measurement station
• Automatic valve clearance measurement station identifies correct shim size required. Various sized shims are stored in dedicated containers, correct shim size container is illuminated for ease of operator identification
• Second valve clearance measurement cycle for correct shim verification
• Manual or automatic tightening of cam cap on cylinder head, torque and angle quality data is captured and recorded