Single-purpose equipment for the automotive industry
Research: Radovan Petrík (MECASYS), Pavol Gužík (MECASYS Design Labs), Jozef Vnenčák - MECASYS CAM Program
Summary
MECASYS has designed, developed and successfully implemented a single-purpose automotive device that provides precise and controlled preheating of an air conditioning system blower propeller.
This innovative solution, built on detailed analysis and advanced technology, enables precise real-time temperature control and significantly improves the quality of the molded joint between the electric motor axis and the propeller.
The project led to a significant optimization of the production cycle, a significant increase in efficiency and overall quality of the final product, thus confirming MECASYS' comprehensive capabilities in the field of automation and precision engineering.
Description of the problem
The client, a leading manufacturer of air conditioning systems for motor vehicles, was facing long-standing reliability and quality issues with a critical press fit joint between the axis of an electric motor and the blower propeller.
Previous manual or inadequately controlled preheating procedures led to inconsistent results, which resulted in increased manufacturing defects and ultimately compromised the reliability of the final product in the harsh operating conditions of motor vehicles.
The lack of the ability to precisely and dynamically control the temperature prior to the actual pressing process was a key factor that prevented the desired quality and repeatability of the joint from being achieved. These inaccuracies led to production delays and complications in the assembly of parts, which required a complex and tailored solution.
The client needed equipment that would eliminate hidden defects that occur during the pressing process and ensure 100% joint quality, thereby reducing operating costs and increasing the overall throughput of the production line.
Solution
MECASYS accepted the challenge and carried out a thorough analysis of the problem, based on which it designed a comprehensive single-purpose device with precise preheating control. We used our own know-how, built up over many years, in the development of single-purpose machines and applied proven methodologies that guarantee the achievement of critical parameters in industrial sectors.
1. Pre-project analysis and optimization of procedures:
Already in the pre-project phase, before the actual start of the implementation, MECASYS analyzed in detail the specific requirements of the client and all submitted documents.
At the same time, we consistently identified their hidden expectations, which is key to delivering a solution that goes beyond just the basic requirements. Based on this comprehensive analysis, our team created multiple scenarios for the solution and implementation of the facility. These scenarios were evaluated in detail in terms of technology risks and their potential impact on the functionality of the facility. In this process, we took full advantage of MECASYS Labs' extensive experience gained through participation in global projects to design and manufacture critical components for various industry segments, including pharmaceutical, aerospace, and construction. This proactive approach allowed us to optimize all procedures and processes to achieve the stated goal of higher efficiency of the final solution.
2. 3D modelling and simulation:
The development of the prototype device was carried out in the 3D environment of SOLIDWORKS software. In the design, we placed key emphasis on simulating the thermal behavior of components and other loads to avoid unwanted deformations and to ensure optimal heat distribution for uniform preheating. This approach allowed us to optimize the stiffness, weight and geometry of the individual fixtures and components of the plant, significantly increasing their stability and reliability in operation. Digital modelling and verification in a 3D environment also eliminated the need for physical prototyping and allowed potential flaws to be detected and eliminated in the early stages of design, resulting in a fast and smooth implementation without unnecessary production downtime.
3. Component manufacturing:
The key parts of the equipment were manufactured on our own state-of-the-art HERMLE 5-axis CNC centres, lathes and EDM countersinks, which are an integral part of the MECASYS product portfolio. The use of these cutting-edge technologies, including EDM and CNC cylindrical grinding to a precision of 0.003 mm, has ensured maximum accuracy and reliability of every component. The entire manufacturing process was carried out in a controlled environment with continuous quality control, guaranteeing that even the most stringent dimensional tolerances were met and ensuring flawless equipment functionality.
4. Control system and automation:
At the heart of the plant is the implemented TIA Portal V17 PLC system, which uses the proprietary MECASYS control software for precise and dynamic real-time temperature control. The entire automation has been comprehensively designed and integrated, including the electrical wiring processed in EPLAN Electric P8 software, ensuring reliable and safe operation. Operation of the plant is intuitive and user-friendly thanks to the touch-sensitive HMI panels, while maximum emphasis has been placed on operator safety. This modular approach to automation ensures flexibility and adaptability for future needs or process changes.
5. Metrology and validation:
To ensure the highest quality and repeatability of results, which is standard for MECASYS, precision metrology has been used in the process of component manufacturing and final assembly of the equipment. All critical components have undergone thorough inspection on HEXAGON METROLOGY Global S series coordinate measuring machines (CMMs). These technologies enable automated five-axis and continuous profile surface measurements, eliminating human error and ensuring detailed inspection of even complex geometries. This systematic approach to verification has ensured the reliability of the entire production process with guaranteed repeatability of results well into the future.
6. Complete integration:
The solution was successfully and seamlessly integrated into the client's existing production line. MECASYS provided not only the supply, but also the complete installation and professional setup of the automation station, minimizing downtime and ensuring a smooth ramp-up of mass production.
Results and benefits
By implementing the proposed single-purpose equipment solution from MECASYS, the client achieved significant and measurable improvements in their production process:
1. Cycle Time Reduction: production cycle time has been reduced by 66%, from the original 90 seconds to an extremely efficient 30 seconds. This has significantly increased the throughput of the production line.
2. Increase in joint quality: there was an unprecedented 100% increase in the quality of the pressed joint, eliminating previous inconsistency problems.
3. Elimination of defects: hidden defects that occurred during the pressing process were completely eliminated, thus increasing the reliability of the final products.
4. Annual cost savings: the client achieved an impressive annual cost saving of €142,000, confirming a rapid return on investment.
5. Increased efficiency and reliability.
6. Production cycle optimization.
7. Reduction of defects and claims: Precise measurement and validated processes eliminated dimensional deviations and reduced defects in the output, thus significantly reducing the number of claims and additional repairs.
Conclusion
This project clearly demonstrated MECASYS' ability to deliver innovative single-purpose equipment and complex automation solutions that combine cutting-edge technology with proprietary products and an emphasis on customer-specific needs. With 19 years of experience and hundreds of completed projects for clients all over the world, MECASYS proves that it can solve even the most demanding technical challenges.
The result is long-term sustainability, higher quality and increased competitiveness of the client's production process. Our approach, based on detailed analysis, in-house development of process scenarios, precision manufacturing and controlled CMM verification, enabled the customer to obtain equipment that significantly reduced assembly risks, eliminated the additional cost of initial inspection and ensured the reliable operation of its high-performance lines.
MECASYS is ready to design, manufacture and implement specialised equipment and fixtures exactly according to your individual needs - reliably, flexibly and with an emphasis on maximum efficiency in your production.
Your needs, Our expertise
If you are looking for a partner that can turn your technology challenges into innovative, reliable and efficient solutions, turn to MECASYS. We offer development, manufacturing and integration of specialized fixtures and automation equipment that will increase the reliability, quality and productivity of your manufacturing or testing processes.
With MECASYS, you get a partner who understands the specifics of your production in detail and can turn them into successful projects - flexibly, professionally and in accordance with the highest standards. We design and deliver tailor-made solutions that support your growth and competitiveness.
Contact us and together we will turn your challenges into concrete results.
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References
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