INDUSTRIES / Automotive / Front Axle Differential Assembly

WHAT WE DID

High performance cars need high performance components and high performance components are assembled on high end machines. This project concerns the assembly of the front axle differential of the Alfa Romeo Julia, more specifically the 550ps Version, which is the launching car configuration.

This machine has been developed as a semi-automated assembly line, which means that all processes are automated except for the component handling. This is done by hand.

The concept of this machine shows the flexibility. The machine can be operated by only 1 operator, but just as well by 8 operators, increasing the output of the line. This of course is ideal in ramp-up situations, or in situation where production numbers are flexible.

The machine consists of a series of 26 modules, each of them having its own task(s). As soon as a differential is started at the first module, all assembly and measurement date is gathered in the central computer, adding up all the tolerances to assure a perfect assembly.
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Finally, every differential is tested on a EOL Test machine integrated in the line. Automatic docking of the differential, bringing it up to full speed under full power and measuring the vibrations that could occur in the car. Vibrations below the set threshold means a finished product that can be packed for shipment.

Key words:

  • - Controlled by a central computer
  • - Every module controlled by a single PLC
  • - Integrated 100% End-of-Line testing
  • - Laser engraving with integrated DMC check
  • - Inline Zeiss Measurement Machine
  • - Manual transport system
  • - Bosch transport system
  • - Oil filling based on flow and high precision scale
  • - Leakage testing
  • - Force and way controlled Presses
  • - Torque and revolution controlled tighteners
  • - Integrated label printer
  • - RFID data handling
  • - Integrated lifting assistance
  • - 225.000 parts per year
  • - 90 seconds cycle time


For more information please contact our Sales
Call +31 45 543 9251 or e-mail sales@gdo-bv.com

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