Dampers assembly and testing line
Lines for the production and testing of dampers occupy a high position in the company's portfolio and have seen many innovations.
|Tube diameter||Typical 30-60 mm|
|Product height||Typical 120-1000 mm|
|Product weight||< 8 kg|
|Robots||1. KUKA - dampers loading/unloading
2. Mitsubishi - gas springs loading/unloading
3. MiR - autonomous logistics robot
|Other||Robotic logistics using AGV / AMR vehicles
Innovative functional test system (CTS)
Innovative gas feeding and rolling system (EPICS)
Gas force test station
Thread quality verification station
Developed in 2020/22 with the support of NCBiR
|Additional functionality||Line adapted to the production and testing of dampers and gas springs|
At the stage of collecting input data for line design, designers and constructors of ELPLC S.A. they consulted the concepts and technical parameters of individual stations on an ongoing basis. Process engineers of dampers factories located all over the world expected a universal machine that would allow the installation of various dampers references. It was also noted that the manufactured dampers have pipes with a diameter of 30 to 60 mm, with a height between 120 and 600 mm. It was necessary to take into account different diameters (from 30 to 300 mm) and the position (from 25 to 100 mm) of the spring bed ring. Individual stations and transport routes of the line had to work with the finished product with a height of 300 to 1000 mm. Additionally, the necessity to maintain a specific gas pressure in the damper (from 0 to 25 bar) and the correct gas force in the damper (from 20 to 500N) was emphasized. In addition, the assembly process required working with pads of various diameters (40-80 mm) with a maximum weight of components of up to 8 kg.
There was a need to meet a number of additional requirements in terms of maintaining parameters such as force (45-150kN), as well as the damping force of the damper (-6500 - 6500N), occurring in its appropriate working position (from 0 to 400mm). It was necessary to keep the speed requirements (from 0.5mm / s to 1000mm / s).
In addition, factory representatives emphasized the need for the control line to perform the basic dimensions of the damper.
A completely autonomous and robotic assembly and testing line was achieved. In principle, it does not require any operator support. The transport of dampers or gas springs to the line is carried out with the use of autonomous AMR or AGV vehicles. The loading operation is performed by six-axis robots. Operations are performed at individual stations. After their completion, the line is unloaded onto an autonomous vehicle. The versatility of the solution deserves attention, as the line can be used both for the production of car dampers and gas springs. The line also uses innovative CTS and EPICS stations.