heat shrink assembly technologycdn.thomasnet.com/ccp/30082609/195701.pdf · 2014. 11. 13. ·...
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Heat Shrink AssemblyTechnology
Heat Shrink Assemblyfrom EMAG is primarily used in the manufacture of high-precision powertrain components. It also works well with workpieces thatare subject to high torquerates and very dynamicloads. Throughout thecontinuing developmentof its systems EMAG isfocusing on the individualsolution. Heat Shrinktechnology leads to asignifi cant reduction incomponent weight and ahigh degree of functionaldensity.
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HEAT SHRINK ASSEMBLY TECHNOLOGY
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This technology is a productiontechnique that does not need moreprocessing. Whether control cams orgears have to be matched with shaftsor shafts need to be fi tted into hous-ings, the heat shrink technique is a safe and continuous process. The advantageof EMAG's technology lies in thepreheating unit, which is geometricallymatched to the workpiece and featuresan essential temperature control.EMAG's patented system is used to joincomplex precision components. Thistechnology can be applied, especially inthe manufacture of shafts.
The advantages of Heat ShrinkAssembly: • A high degree of precision that
requires no post-processing operation • Component weight reductions which
leads to savings in material • No component deformation after
joining • It is possible to join diverse materials • Freely selectable component
sequences • Freely selectable angular and axial
positions • In case of product changes, resetting
is quick
Heat Shrink Assembly Technology.
The process.
cold
preheated
joined andpositioned
State
Hub, precision component,machined with shrink-on allowance
Hub preheated, joiningclearance 0.015 mm
Hub and shaft joined –form fi t
Component
Shaft, precision component
J O I N I N G
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Method 1 – Shaft fitted into hub.
Shaft is insertedinto hub
Hub is preheatedand clamped
Hub is preheated andmoved over shaft
Shaft is clamped
Method 2 – Hub fitted onto shaft.
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The joining process for composite camshafts.
EMAG's Heat Shrink Assembly ischaracterized by a stress-free joiningprocess. The best combination of a robotand specially designed gripper systemmake it possible to work with a joiningclearance of < 15 μm. The fl exibility ofthis concept allows for greater freedomin the design of camshafts and has itsadvantage in medium batch productionwith frequent resetting to accommodatediff erent shafts. The Heat ShrinkAssembly process combines fl exibilityand productivity, as the user benefi ts
from constructional, production-specifi cfreedom and from short cycle times.While one cam is fi tted, the next one isalready being preheated. By equippingthe joining machine with a number ofpreheating units the process can bescaled to suit specifi c requirements.
The advantages composite camshaftsprovide: • A reduction in costs • A reduction in component weight • The cams can be of diff erent
materials • Greater fl exibility in production • New cam geometries, such as
negative radii, can easily beaccommodated
Camshafts for passenger cars
J O I N I N G
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Camshafts for commercial vehicles
Camshafts for small-power andpassenger car engines
Reducing the number of downstreamoperations:The high precision of the compositecamshaft allows for the cam contourgrinding operation to be drasticallyreduced, or – where precision cams areemployed – eliminated altogether.Another advantage in using this methodis the possibility to combine diff erentmaterials in the manufacture of theshaft. For instance, forged cams (e.g. in100Cr6) can be used alongside sinteredcams that do not call for a subsequentgrinding operation.
Ancillary components, such as plugsor endpieces, can – just like the shaftitself – be made of more advantageousmaterials. This allows for the camshaftto be designed to suit the requirementsof the particular engine and to beoptimized concerning loading capacityand manufacturing costs.
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The manufacturing process for composite drive shafts.
Heat Shrink Assembly of gear shaftsensure that they are compact and havea high degree of functional density, asthe gears can be brought right up closeto the shoulders. This ensures that shaftvariations are easy to manufacture.And the use of hollow shafts meets thedemands for weight reduction. Rotatingmass is reduced signifi cantly, withoutany negative eff ect on the shaft'sresilience.
Thermal joining technology off ers designengineers new opportunities to ensurethat gear shafts are compact, lightweightand of the right functional density. Theresults are individual solutions for everyrequirement.
Assembly line for drive shafts
Assembly line for gearsfi tted on camshafts
Assembly line for crankshafts
J O I N I N G
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Preheating systems AWG.
The advantages: • Component-matching system
geometries for optimal heat transfer • The joining temperature remains
constant throughout the process • Individually controlled preheating
units • State-of-the-art measuring and control
technology guarantees minimalenergy consumption and accuratetemperature control
• Simple to operate; with maximumprocess integrity assured
Sturdy, compact metal housing with solidworktop in aluminium and integrated prewarmingunits
Technical data: • Power supply: CEE-plug
(5-pole, 16 A) / shockproof plug • Protection class: mechanics IP40,
electrics IP54 • Application-dependent parameters:
cycle time, heat output and preheating time per component
• Choice of housings: W x D x H(standard)a) 500 x 500 x 400 mmb) 700 x 500 x 400 mmc) 900 x 500 x 400 mm(dependent on workpiece size)
• Preheating unit:a) up to 40 mm internal diameterb) > 40 mm to 70 mm internal diameterc) > 70 mm to 120 mm internal diameter
J O I N I N G
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The way to the best machining solutionbegins with great preparation, i.e. thedefi nition and selection of the propertechnology. We off er a competentadvisory service in all questions concerning our Heat Shrink Assembly process and will create a customized comprehensive concept that covers everything from workpiece and technol-ogy to machining sequence optimization and assembly parameters / sequence. • Checking the possibility to join
specifi c workpieces and assemblies • Checking tolerances and establishing
the way to join the workpieces • Identifying geometric details and
surface fi nish
Engineering and advisory service.
Prototyping / laboratory.
From prototyping to the testing of newdevelopments – the EMAG heat shrinklaboratory analyzes component geometries with the focus on defi ning the optimal cost-benefi t ratio. • Construction of prototypes for initial
sample inspection • Production of a pilot series • Establishing transmissible moments • Cycle time studies • Establishing an achievable machine
capability
• Calculating transmissible torque andaxial forces
• Design changes between existingcomponents and composite version
• Support in product development, witha view to the joining capabilities ofthe EMAG process
• Identifi cation of the appropriatepreheating technology
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www.emag.com
EMAGGruppen-Vertriebs- und Service GmbH
SalachAustrasse 2473084 SalachGermanyPhone: +49 7162 17-0Fax: +49 7162 17-820E-mail: [email protected]
FrankfurtMartin-Behaim-Strasse 1263263 Neu-IsenburgGermanyPhone: +49 6102 88245-0Fax: +49 6102 88245-412E-mail: [email protected]
CologneRobert-Perthel-Strasse 7950739 KölnGermanyPhone: +49 7162 17-0Fax: +49 7162 17-820E-mail: [email protected]
LeipzigPittlerstrasse 2604159 LeipzigGermanyPhone: +49 341 4666-0Fax: +49 341 4666-014E-mail: [email protected]
MunichZamdorferstrasse 10081677 MünchenGermanyPhone: +49 89 99886-250Fax: +49 89 99886-160E-mail: [email protected]
AustriaGlaneckerweg 15400 HalleinAustriaPhone: +43 6245 76023-0Fax: +43 6245 76023-20E-mail: [email protected]
DenmarkHorsvangen 317120 Vejle ØDenmarkPhone: +45 75 854854Fax: +45 75 816276E-mail: [email protected]
NODIER EMAG INDUSTRIE2, Parc des Fontenelles78870 BaillyFrancePhone: +33 130 8047-70Fax: +33 130 8047-69E-mail: [email protected]
EMAG MAQUINAS HERRAMIENTA S.L.Pasaje Arrahona, no 18Polígono Industrial Santiga08210 Barberà del Vallès (Barcelona)Spain Phone: +34 93 7195080Fax: +34 93 7297107E-mail: [email protected]
ZETA EMAG SrlViale Longarone 41/A20080 Zibido S.Giacomo (MI)ItalyPhone: +39 02 905942-1Fax: +39 02 905942-22E-mail: [email protected]
EMAG (UK) Ltd.Chestnut House, Kingswood Business ParkHolyhead RoadAlbrightonWolverhampton WV7 3AUGreat BritainPhone: +44 1902 37609-0Fax: +44 1902 37609-1E-mail: [email protected]
EMAG L.L.C. USA38800 Grand River AvenueFarmington Hills, MI 48335 USAPhone: +1 248 477-7440Fax: +1 248 477-7784E-mail: [email protected]
EMAG MEXICOColina de la Umbria 1053140 Boulevares Naucalpan Edo. de MèxicoMexicoPhone: +52 55 5374266-5Fax: +52 55 5374266-4E-mail: [email protected]
EMAG DO BRASIL Ltda.Rua Schilling, 413Vila Leopoldina05302-001 São PauloSP, BrazilPhone: +55 11 38370145Fax: +55 11 38370145E-mail: [email protected]
EMAG INDIA Pvt. Ltd.Technology Centre,No17/G/46-3 & 17/G/46-3-1,Industrial Suburb, II Stage,Yeshwanthpur,Bangalore 560022.IndiaPhone: +91 80 42544422Fax: +91 80 42544440E-mail: [email protected]
EMAG SOUTH AFRICAP.O. Box 2900Kempton Park 1620Rep. South AfricaPhone: +27 11 39350-70Fax: +27 11 39350-64E-mail: [email protected]
EMAG Machine Tools (Taicang) Co., Ltd.Building 3, Cang Neng Europe & American Technology ParkNo. 8 Lou Jiang Rd. (N.)215400 Taicang P.R. ChinaPhone: +86 512 5357-4098 Fax: +86 512 5357-5399E-mail: [email protected]
EMAG KOREA Ltd.Rm204, Biz center, SKn Technopark, 124 Sagimakgol-ro, Sangdaewon-dong, Joongwon-gu,Seongnam City, Gyeonggi-do, 462-721,South KoreaPhone: +82 31 776-4415Fax: +82 31 776-4419E-mail: [email protected]
TAKAMAZ EMAG Ltd.1-8 Asahigaoka Hakusan-City Ishikawa Japan, 924-0004 JapanPhone: +81 76 274-1409Fax: +81 76 274-8530E-mail: [email protected]
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PolandSpółka Z Ograniczoną Odpowiedziàlnością Oddzial w PolsceMiodowa 1400-246 Warsaw PolandPhone: +43 6245 76023-15Fax: +43 6245 76023-20
Russiaul. Akademika Chelomeya 3/2117630 MoscowRussiaPhone: +7 495 287 0960Fax: +7 495 287 0961E-mail: [email protected]
Belarusul. Timirjazeva, 65 B, Office 1101220035 MinskBelarusPhone: +375 17 2547730Fax: +375 17 2547730E-mail: [email protected]
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