Process monitoring equipment used in automotive assembly

DURA Automotive Systems Reiche GmbH is using measurement technology from HBM to ensure that a steering coupling meets the high production and quality control standards required. This steering column is used in the latest Mercedes-Benz SLS AMG sports car that has a 420kW, 6.3-litre engine that accelerates it from 0 to 100km/h in just 3.8s.

The steering coupling, which connects the steering wheel to the steering gear, comprises a corrugated tube, a smooth tube and a double universal joint. This constant-velocity joint, which is manually assembled by DURA, has a decisive influence on steering precision.

To ensure the highly responsive steering required for the Mercedes Benz SLS AMG, all components of the steering column are checked using HBM's equipment. Complete traceability of every working step is guaranteed with the HBM hardware and software used because each steering coupling has a serial number.

Process monitoring

The bending torque in the joint is checked using HBM's PW4M platform load cell. This is also used to measure movement in both directions on a test bench. Once the joint has been checked, the tubes are fitted with threaded inserts. The force and displacement during the press-fit process is carefully monitored using HBM's MP85A FastPress process monitoring system to maintain the required quality.

Measured data is evaluated in the process controller to ensure that press forces lie within the specified tolerance window. The process controller delivers an 'OK' signal and transmits the measured process data simultaneously to the test bench control computer via the network.

Finally, the torque on any screws is measured and recorded during the tightening of screw fittings on the parts. All process parameters are recorded and maintained in a database.