Measuring station and assembly station for die-cast parts

The project

What can be done when each individual component is particularly costly to manufacture and errors in assembly can quickly lead to further costs? AUTFORCE has developed a suitable solution for a leading manufacturer of aluminum die-cast components: a testing system with two coordinated stations, a measuring station and an assembly station.

At the first station (measuring station or inspection fixture) each component is carefully checked for dimensional accuracy and completeness. Only then does assembly take place, during which bolts, screws, and brackets are added. Finally, the component is checked once again to ensure that the finished assembly meets all quality requirements. This double inspection process is particularly important for high-quality die-cast parts in order to avoid material and assembly costs in the event of a defect.

The progress of the project is particularly impressive: initial tests were carried out just four months after the order was received. After only six months, the entire system was ready for use and was delivered to the customer. This was made possible by a proven partner network, flexibility within the project team, and close coordination across all project phases.

Key Facts

• 2 stations: measuring station and assembly station
• Component testing before and after assembly
• 27 tactile measuring points, tolerances up to ±0.2 mm
• Combination of automated and manual assembly
• Traceability: DMC code on every component
• Initial tests after 4 months, delivery after 6 months

Testing and assembly process

Each aluminum die-cast part undergoes a standardized three-step process:

• Initial inspection at the measuring station: Measurement and completeness check of the raw part
• Assembly at the assembly station: automatic joining, screwing, and manual final assembly
• Final inspection at the measuring station: final check of the assembled components

The double check ensures that only flawless parts are assembled and passed on, and that no deformations occur during assembly. Each component can be clearly traced via a data matrix code (DMC).

Inspection before assembly

Before assembly, each component is checked for dimensional accuracy and completeness.

• Insertion and positioning
  The component is inserted manually, positioned correctly, and checked by sensors to ensure it is seated properly.
• Measurement points and tolerances
  A total of 27 measurement points are recorded, two of which have a particularly narrow tolerance of ±0.2 mm; laser and light sensors also check for completeness.
• Automatic process with safety monitoring
  The testing process is fully automatic, while a safety light curtain secures the work area.
• Transfer to the assembly station
  Only tested and fault-free components are transferred by the operator for assembly.

Automated and manual assembly

The assembly process combines automated procedures with specific manual steps.

• Inserting the component
  The operator inserts the component according to the markings, and sensors check the exact position.
• Tensioning and start of assembly
  After leaving the work area, automatic tensioning and assembly are triggered by a start button, and safety devices protect the operator.
• Pressing in pins
  Several pins are automatically pressed into prepared holes by pneumohydraulic drives. Force-displacement monitoring ensures that each pin is seated correctly and reliably.
• Screwing together the components
  Some of the screws are first separated and fed automatically, then assembled automatically, while the rest are added manually by the operator. Sensors check that all screws are positioned correctly.
• Completion and transfer to final inspection
  After assembly, the component is removed and transferred to the final measuring station.

Inspection after assembly

The final inspection ensures the quality of the assembled component. Only fully tested components are released for further processing.

• Re-measurement of the 27 measuring points
  The measurement results are compared with the initial test to ensure dimensional accuracy.
• Checking for the presence of all press-fit pins
  All press-fit pins are specifically checked and documented.
• Measurement control with ±0.4 mm tolerance
  Two defined measurements are checked using differential measurement.
• Checking the position and alignment of the brackets
  The correct position of the mounted brackets is checked one last time.