Semi-automatic injector assembly system achieves flexibility and accuracy for Delphi

Citation

(2002), "Semi-automatic injector assembly system achieves flexibility and accuracy for Delphi", Industrial Robot, Vol. 29 No. 1. https://doi.org/10.1108/ir.2002.04929aaf.006

Semi-automatic injector assembly system achieves flexibility and accuracy for Delphi

Keywords: Assembly, Delphi

Modular Automation has designed and built a semi-automatic, truck fuel injector assembly system for Delphi Diesel Systems that achieves the necessary accuracy for the correct operation of a number of different injector variants.

The Delphi E1 Advanced Fuel System is a leading edge product that delivers precisely the correct amount of fuel to each cylinder in turn under all driving conditions. The system allows Delphi to manufacture products that satisfy the emission regulations of individual countries and marks a major leap forward in diesel engine performance and fuel efficiency. It is currently being supplied for use on the Volvo FH12.

The Modular Automation system is a series of linked work stations that ensure the assembly work is carried out in the correct sequence and that only components for the correct variant can be used at any time.

The most critical part of the process is the assembly of the injector's solenoid valve. The unit uses precision shims within the actuator body to adjust response time and achieve a complete injector assembly that operates correctly first time and does not need subsequent calibration (Plate 8).

Plate 8 This new assembly system, built by Modular Automation for Delphi, assembles multiple variants of diesel engine injectors to the correct tolerance

The process starts by determining the correct shim thickness required. To do this, the operator selects a valve assembly and a pre-load spring and assembles them into a test fixture. A setting station then selects a shim of the correct thickness to provide the necessary operating characteristics as determined by the design requirements. The operator then selects and fits the appropriate shim and the complete assembly moves to the injector build line.

The process continues through various linked stations to assemble the top end of the injector followed by the actuator and nozzle. A later station also performs a 2-stage leak test to ensure that all components have been fitted correctly.

Information regarding each assembly is recorded. This information identifies each part of the assembly and ensures that the operator can only access the correct parts for each variant. (For example, a different nozzle controls each variant.) The system also records the product test results and awards a “pass flag” to all good assemblies. After testing, a final station supplied by Modular Automation laser marks each product with its unique production information.

All workstations are connected to the Delphi plant server via Ethernet. Detailed build histories are automatically created and stored on the server for every injector produced.

Throughout the process, Modular Automation made sure that all parts were placed ergonomically, that there was no opportunity for parts to be mixed up and that damage to parts was prevented. It was also a prime requirement from Delphi that the breakdown of one station should not affect the performance of other station up or downstream.

Modular Automation has vast experience at developing innovative assembly systems using a modular approach and trusted technology. By approaching its business in this practical way it ensures that its systems are realistically priced, effective and utterly reliable. Modular Automation has also designed this system to be easily adapted to produce the next generation product when required to do so.

All business enquiries to: William Bourn, Modular Automation, Talbot Way, Small Heath Business Park, Birmingham, B10 0HS, UK. Tel: 0121 766 7979; Fax: 0121 766 6385; Email: bourn@modular.co.uk