Automation in Hydraulic Press for Automotive Applications: Oil Plug, Oil Seal, Impeller Shaft, and Water Seal Pressing

In the automotive industry, precision and consistency are crucial for ensuring the performance and reliability of components. Processes such as oil plug pressing, oil seal pressing, impeller shaft pressing, and water seal pressing involve high accuracy and force, making hydraulic presses the ideal equipment for these applications. Automation of hydraulic presses in these processes not only improves productivity but also ensures consistency and traceability, which are essential for automotive standards.

Below are the key automation features for these applications:

1. Individual Display on Each Press

Each hydraulic press is equipped with its own dedicated display, allowing operators to monitor specific parameters such as force, displacement, and cycle time in real-time. This ensures better control over the pressing operation and improves process visibility for individual tasks like oil plug pressing or water seal insertion.

2. Load Cell for Individual Force Measurement

Each press includes a load cell that measures the pressing force applied to each part. This feature ensures that the correct force is applied, which is critical for delicate operations like oil seal pressing and impeller shaft assembly. Accurate force measurement guarantees the parts are neither over-pressed nor under-pressed, maintaining component integrity and performance.

3. Common LVDT (Linear Variable Differential Transformer) for Displacement Measurement

A common LVDT system measures the displacement or movement of the press. This feature is important for monitoring the precise movement required in tasks such as oil plug or shaft pressing, where accurate positioning directly affects the functionality of the final assembly.

4. Display for Graph Plotting and Data Storage

The display is integrated with software that plots graphs for load vs. displacement, providing a clear visual representation of each press cycle. The data is stored for quality control, traceability, and further analysis. This is especially useful in high-precision processes like oil seal or water seal pressing, where deviations in load or displacement can indicate defects.

5. PLC Communication

Each hydraulic press communicates with a programmable logic controller (PLC) to coordinate the pressing operation and ensure proper sequencing. This integration is essential for automating multiple presses simultaneously and managing complex tasks like impeller shaft pressing in an assembly line.

6. Separate Display for Load Cell Graph with Backend Software

Each load cell has a dedicated display to show a load vs. displacement graph, which is accessible through the backend software. This allows operators to closely monitor the pressing process, ensuring that force and displacement remain within predefined limits for components like oil seals or shafts.

7. Result Communication with Machine PLC

The result from the load cell and LVDT sensors, including force and displacement data, is communicated with the machine’s PLC. This ensures that any deviation from set parameters is immediately flagged, halting the process if necessary. This feature is vital for maintaining product quality in operations such as oil plug pressing or impeller shaft assembly.

8. Window Settings for Load Vs Displacement via Display

Operators can set and adjust load vs. displacement window settings directly through the display. This flexibility ensures that the press can be quickly configured for different components, whether it’s an oil plug, water seal, or impeller shaft, ensuring consistent production without manual intervention.

9. Evaluation and Monitoring through Display

The system evaluates load vs. displacement results in real time, providing immediate feedback on whether the press operation was successful or if any deviations occurred. This is critical for detecting defects early in the process, especially for sensitive components like oil seals and water seals, where incorrect pressing can lead to leaks or failures.

10. Data Storage in PLC and Sharing with MES

The data from each press cycle is stored in the PLC and communicated with the Manufacturing Execution System (MES) for further analysis and traceability. The MES system acknowledges the completion of a successful press operation before allowing the next cycle to start, ensuring traceability and quality control across the production line.

11. Data Search Facility on Display

Operators can search for historical data on the display, enabling them to review past operations and diagnose any issues that may have arisen. This feature is crucial for continuous process improvement and ensuring that each pressing operation meets stringent automotive quality standards.

12. Scanner Integration with PLC for Part Number Tracking

A scanner integrated with the PLC allows pressing data to be stored against the specific part number. This enables traceability, ensuring that every oil plug, seal, or shaft is pressed according to its exact specifications, and that data for each component is available for review.

13. Mechanical Stopper for Safety

All hydraulic presses are equipped with a mechanical stopper to ensure operator safety and prevent over-pressing, protecting both the equipment and components during critical operations such as impeller shaft or water seal pressing.

Conclusion

Automating hydraulic presses for oil plug, oil seal, impeller shaft, and water seal pressing in the automotive industry enhances precision, consistency, and traceability. By integrating load cells, LVDT systems, data storage, and PLC communication, manufacturers can achieve optimal performance while ensuring compliance with stringent automotive standards. This level of automation improves productivity, reduces errors, and maintains high-quality output essential for modern automotive manufacturing processes.