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Leak Testing and Special Application for assembly …

LeakTestingandSpecialApplicationforassem blylines4 Leak TestingA modern manufacturing line is designed todeliver a final product with high reliability andalways increasing performances. The leak test-ing is now implemented as one of the methodsfor process monitoring and quality control: anaccurate leak test can surely grant the productquality in terms of reliability, performances testingis used in-line in the machiningprocess and/or at assembly having acquired the company TRACE(market leader with over 350 systems installedin France and specialized in helium applica-tions), becomes the right partner able to pro-vide leak test stations to be used in the machin-ing process and/or at assembly TRACE are actually able to supply leaktesting stations tailored to the Customer sneeds.

Leak Testing Examples of installed applications 6 Leak test machine for engine block water, low pressure and high pressure oil circuit • Gantry loader solution

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Transcription of Leak Testing and Special Application for assembly …

1 LeakTestingandSpecialApplicationforassem blylines4 Leak TestingA modern manufacturing line is designed todeliver a final product with high reliability andalways increasing performances. The leak test-ing is now implemented as one of the methodsfor process monitoring and quality control: anaccurate leak test can surely grant the productquality in terms of reliability, performances testingis used in-line in the machiningprocess and/or at assembly having acquired the company TRACE(market leader with over 350 systems installedin France and specialized in helium applica-tions), becomes the right partner able to pro-vide leak test stations to be used in the machin-ing process and/or at assembly TRACE are actually able to supply leaktesting stations tailored to the Customer sneeds.

2 Automatic machines with roller/palletconveyors as well as gantry loader(suitable for in-line applications ) Automatic machines with robot automa-tion(suitable for assembly line integration) Machines with rotary table(suitable to speed-up the loading/unloading operations) Machines with automatic sealing toolsexchange(flexible for different part families) Machines with sealing tools carriage (easily and quickly re-toolable for differentpart families) Manual stations for final inspection oras back-up station for repair loops Integrated applications (multi stations)for assembly lines( assembly + leak test + dimensional inspection) Tracer gas vacuum chambers(high performances for very little leaks) Tracer gas sniffing stations(suitable for leaks localization)Leak Testing5 Few reasons to perform the leak Testing Ensure integrity of checked parts Ensure good functionality Avoid contamination problems Reduce reworking Reduce production costs Total quality assurance of the partsWhere and how leaks occur:after casting Porosity Flaws/cracksafter machining Machining errors Part defectsafter assembling Missing seals Defective seals Wrong positioning Wrong assemblingLeak Testing techniques Part pressurization and/or water dunk Pressure decay measurement.

3 - by relative transducer- by differential transducer Flow measurement Mass Spectrometer for heliumTypical checks Oil circuit leakage Water circuit leakage Fuel circuit leakage Gasket leakage Fluid circuit integrityTypical part for which the leak test is required Engine block Cylinder head Gear case Differential case Crankshaft & camshaft Oil, water and fuel pumps Manifolds Valves Brake components Gas components OthersLeak TestingExamples of installed applications6 Leak test machine for engine block water,low pressure and high pressure oil circuit Gantry loader solution Two different part types (4 cylinders) Automatic retooling of sealing assemblies Test pressure 1,5/0,6 bar Twin station machine for cycle time constraintIn-line automatic machine for enginehead water circuit, fuel circuit and oilcircuit Roller conveyor solution Three different part types (6 cylinders) Automatic retooling of sealing assemblies Test pressure 1,5 barOil, water, injection circuit leak teststation for assembled engine and fillingoil station Pallet conveyor solution Two engine models Two stations Flow measures and decay measureIn-line automatic machine for engineblock water jacket Roller conveyor solution Three different part types (6 cylinders)

4 Automatic retooling of sealing assemblies Test pressure 1,5 barLeak TestingExamples of installed applications7In-line automatic machine for engineheads front seal Roller conveyor solution Relative vacuum test Camshaft turning torque checking Part repair baysIn-line automatic machine forauxiliary gears assembly oil circuit Roller conveyor solution Working island with pallet line Different part typologies Oil circuit leak test and shaft turningtorque checkingEngine block front seal leak teststation Pallet conveyor solution In-line vacuum test with part conveyedon pallet Measure result recorded on radiofrequency identification (RFID) system8-16V cylinder valve leak test station Roller conveyor solution Heads assembly line Two stations for the two different heads Flow measureLeak TestingExamples of installed applications8 assembly and leak test machine for4 and 5 cylinder engine heads1^station Oil circuit leak test Oil circuit continuity test2^station Oil plug screw-driving Oil praying plug screw-driving3^station Water circuit leak test Oil plug leak testAutomatic machine for four cylinderengine block circuit Oil circuit leak test Two stations.

5 Each dedicated to a parttypology Loading and unloading by gantry Part translation by lift and carry beam Hydraulically poweredLeak TestingExamples of installed applications9 Four cylinder engine block waterjacket and oil plug leak test station(integrated into the final measuringmachine) Pallet conveyor solution Water jacket leak test Two stations, each dedicated to a parttypologyOil pump body leak test Robot handled solution Oil pump body leak testRevolving table machine, manualload/unload, for leak test of engineheads after cubing1^station Part station Deck face water circuit holes presencecheck2^station Water circuit leak test Good part markingValve leak test Valve run-in and test for 16 valve engineheadsLeak TestingExamples of installed applications10 Engine block front seal and oil plugsleak test station Long block Vacuum testEngine block rear seal leaktest station Engine block rear seal leak teststation Thread hub screwingEngine block leak test Water jacket leak test Dunk tank for locating leak byrolling partLeak test with air and part dunk Leak test with air Part dunk and repairing station fortruck and tractor engine blocksLeak TestingExamples of

6 Installed applications11 Power steering gear body leak test Manual load/unload Leak test Dunk tank lifting for locating leak Part markingV6 engone block front oil sealleak test Vacuum test Fixture is hung above the lineCam carrier oil circuit leak test 4 cylinder cam carrier Manual load/unloadAssembly station and leak testmachine for 4 and 5 cylinder heads Repair stationLeak TestingExamples of installed applications12 Leak test machine for engine blockwater, oil low pressure andhigh pressure circuits Robot handled solution Machines with revolving table (high speed) Two part families 1500 pcs/day About 30 machines of this model installedLeak test machine for cylinder headwater and high pressure oil circuits Robot handled solution Different part families Re-toolable solution 1200 pcs/day About 15 machines of this model installedLeak test machine for cylinder headcover high pressure oil circuit Robot handled solution Two part families Manual loading at front sideLeak test machine for cylinder headand camshaft cover water.

7 Low andhigh pressure oil circuits Robot handled solution 1250 pcs/day 7 machines on this model installedLeak TestingExamples of installed applications13 Leak test machine for assembledengine water and oil circuits Pallet conveyor solution Two part families 2000 pcs/dayLeak test machine for engine block Pallet conveyor solutionMachines with robot automation( assembly line integration) Area with one robot anc 2 testmachines for 2500 pcs/dayMachines with robot automation( assembly line integration) Robotized area with 2 leak testmachines and sorted accumulation for2500 pcs/dayHelium test Applications14 Leak test cylinder head directinjection fuel circuit Robot handled solution Vacuum chamber solution with tracergas High performance (high resolution) Twin station machine for cycle timeconstraintHelium leak test back-up station(sniffing method)Leak test for cylinder head directinjection fuel circuit Pallet conveyor solution Sniffing cycle with tracer gas for leaklocalization Robot handled sniffing cycle High performance (high resolution)

8 Twin station machine for cycle timeconstraintLeak test for cylinder head directinjection fuel circuit Robot handled solution Vacuum chamber solution High performance (high resolution) Special Applicationfor assembly lines15 Machine for oil filling (N 4 machines already installed) Automatic gear assembly line Cycle time: 94 secOil suction automatic station afterhot test machine Automatic engine assembly line Cycle time: 54 secCylinder head cam shaft front ringseal assembly station Automatic engine assembly line Cycle time: 40 secAssembly station for caps pressfitting and screw-driving with capsfeeding unitsSpecial Applicationfor assembly lines16 Automatic assembly area for cylinderblock cap press fitting (2 stations) andleak test station (water, low pressureand high pressure oil circuit)Crankshaft oil gallery flowinspection machine Cycle time: 18 secAutomatic dimensional inspectionstation in automatic gear boxassembly line Cycle time: 22 secAutomatic dimensional inspectionstation in automatic gear boxassembly line Cycle time.

9 22 secSpecial Applicationfor assembly lines1716V camcarrier screw driving andfront seal leak test station 16V head assembly line Fly-roller conveyor Relative vacuum testMulti station machine for freeze capspress fitting, oil plug screw driving andoil and water circuits leak test for 4cylinder engine head1^station Main oil channel oil plugs screw driving Loctite spraying on freeze cap seat Freeze cap press fitting Screw-driving assembly moved by CNC slides Thread oil plugs and freeze caps fed bypneumatic shot units2^station Oil plugs screw-driving for tightening oil cir-cuit Loctite spraying on freeze cap seat Freeze cap press fitting Screw-driving assembly moved by CNC slides Thread oil plugs and freeze caps fed bypneumatic shot units3^station Water circuit leak test Low pressure oil circuit leak testInstruments18 LTE Delta SIt s a reliable and easy to use instrument forleak s based

10 On the pressure decay to 16 resident measuring pressure ranges = +1 Bar + 6 Barrelative ( Special on request).RS 232 serial interface for data 1 Sabsolute measure. Available versionwith automatic or manual pressure 3 Sdifferential measure related to a ref-erence volume. With relative pressure trans-ducer for test pressure and a differentialtransducer for leak Top Bench version: mm 320(w)x175(h)x440(d)Weight: 12 KgE9066 - WINATEIt


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