components and require press force from both directions to compress the conducting powder inside into a solid. As you get closer to the target force, in the range of 50,000
lb (22,500 kg), EMAPs are smart enough to slow down and target the force exactly. In battery manufacturing, pressing with too much force has as many drawbacks as pressing with too little. In addition, in order to eliminate problems from occurring when you release the pressure, it is critical that both sides are pressed with the same amount of force and to the same distance. Te EMAPs can be synchronized, and com- municate with each other to stay synchronized, and they can generate the force and position curves to prove it.
With smarter assembly systems, manufacturers can press to a programmable position, press to an offset, or press to a rate of change in order to achieve consistent part success.
Gearboxes and Backlash In-process monitoring and real-time response to variations
in press-fit assembly can do more than simply spot mistakes. It can guarantee that a bad product never leaves the station. Take the issue of backlash in gear assemblies. Backlash
testing is most oſten approached in one of two ways: static or dynamic. Static testing involves the output, or final driving gear, being held in a fixed position while torque is applied in both directions to the input gear. Te calculated difference is the static backlash of that particular gear assembly at that particular mesh point. Dynamic testing involves the gear being rotated to incorporate all mesh points as torque is ap- plied. With Rotational Electro-Mechanical Assembly Presses, each with high-precision rotary encoders, all forces can be captured, stored, plotted, and displayed in both directions. Tis data can then be used to determine minimum, average, and maximum values for go or no-go decisions before the as- sembly ever leaves the station. Since the REMAP’s ram rotates and can capture rotational position information in addition to torque, press force, and angle, it becomes an exceptional tool for torque-and-turn tests. It can establish breakaway torque (the restraining torque that has to be overcome to start rota- tion of one ring of the bearing while the other remains station- ary), average running torque (the mean torque encountered during rotation), and peak running torque, all under varying axial load conditions. All data can be collected and plotted in torque and force curves. Adding sensing and data-gathering capabilities to press-fit
Preloading and monitoring force, position, and torque limits assures critical bearing quality.
applications does not have to be a science-project nightmare of myriad custom components. Quite the contrary, establish- ing intelligent press-fit systems that can monitor and establish upper and lower control limits for pressing, testing, and as- sembling an infinite number of applications is limited only by the engineer’s imagination. Manufacturers spend enormous sums of money to produce
ultraprecise parts that are assembled with technologies that have not changed significantly in a century. Why not spend less on the components and assemble them with a smart system that can accommodate dimensional variations and still produce functional products? All that’s needed to make that happen is a willingness to step back and look at the pos- sibilities inherent in today’s intelligent assembly technologies. Function is the consumer’s measure of quality, and function ought to be the manufacturer’s as well.
Motorized Vehicle Manufacturing 45
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