Project 474
Automation of
liquid seals
- increases manufacturing quality
- reduces waste
- ensures process stability
challenge
Optimisation of the sealing function
Leaks repeatedly occurred in the area of the three-way junction (crankcase, oil pan top, end cap). The solid seal used previously was unable to reliably ensure the necessary sealing under height tolerances and temperature fluctuations. the sealing function
objective
Apply liquid sealant automatically
The aim was to prevent the sealant from being displaced after the components had been joined together, while at the same time ensuring that there was sufficient quantity to compensate for height tolerances. In addition to the solid seal, a liquid seal was to be applied automatically – precisely in terms of position and volume.
our solution
Customised dosing system
DoBoTech developed a customised dosing system in its in-house technical centre for integration into the existing production line.
Key features of the system:
- Seamless integration: Designed for installation behind the existing belt system with pneumatic feed.
- Ergonomics & safety: Operation via safe two-hand control, supplemented by a safety foot mat.
- Camera system for position monitoring: Position detection and automatic offset correction via camera to ensure correct application position.
- Repeatable positioning: Pneumatic bearings and X-Y floating ensure consistently precise operation.
- Automatic variant adjustment: Adjustment to different component variants is carried out via pneumatically adjustable indexing.
- Efficient material supply: Alternating operation with two 310 ml cartridges for uninterrupted operation.
results
Benefit
- Less waste: Significantly reduced leaks in series production.
- Greater process reliability: Reproducible quality for every component.
- Efficiency gains: Continuous production without downtime.
- Flexibility: One system for multiple variants.
Numbers
95% reduction in failure and rework rates through automation and the use of appropriate dosing technology
75% increase in production speed through process automation
99% process reliability through simultaneous process monitoring and control
75% conceptual preparatory work for the series production process
conclusion
Summary and outlook
This solution impressively demonstrates how targeted automation and innovative special-purpose machine construction can increase production standards and cost-effectiveness.
Due to the successful solution, further automation steps are being examined. The goal is the fully automatic integration of the station into the manufacturing process.
