Automated
Montagelinie für Hinterachsdifferentiale

Efficient linking of assembly stations incl. laser welding system

Flexibility & ergonomics with full automation

Die vollautomatische Vormontage der Zwischenlagen wird von vier Robotern durchgeführt. Das Bauteilhandling zwischen den einzelnen Prozessschritten sowie die Übergabe an die nachfolgende Montagelinie wird mit zusätzlichen Robotern und einem vollautomatischen Transfersystem realisiert. Component handling between the individual process steps as well as transfer to the subsequent assembly line is realized with additional robots and a fully automatic transfer system. The fully automatic assembly of the compensation housings relieves the operating personnel of monotonous and physically strenuous work. This criterion was an explicit task of the customer, because the turning of the bevel gears was done manually on the previous system. The previously jerky and force-intensive movements for the employees are no longer necessary, and ergonomically optimized activities have been created at the insertion stations of the new system instead.

Thanks to universal fixtures and job control, a high number of variants can be realized without having to set up the system. The customer can create additional variants independently.

Innovative welding processes

The connection between the differential drive and the ring gear is made by a laser welding process

In preparation for laser welding, the corresponding processing surfaces are cleaned in a laser clean module and the surface is prepared for further processing. After pressing the crown wheel onto the balance housing, the laser welding process takes place. The process is checked by the integrated online process monitoring. The seam finding system determines the distance to the outer edge of the differential housing and checks it in relation to the seam position. At the same time, the laser power is monitored during welding. Afterwards, the weld seam and the crown wheel pressure side are cleaned of flue and small weld spatter in the brushing station.

Quality Check

By means of a press-off & ultrasonic testing station, the quality of the weld seam is checked in the cell. During ultrasonic testing, the weld is inspected for flaws and it is checked whether cracks may have formed in the weld due to the previous stress of the press-off test. In addition, a weld seam testing system is used to check the seam top bead in a measuring cycle with profile evaluation.

Component buffer for more flexibility to the downstream line

In the sequence memory at the end of the assembly process, the components are buffered until further processing and only placed on the workpiece carrier of the downstream line by the robot when required. On the transfer system, NIO parts can also be rejected or externally manufactured parts can be fed into the buffer.