Assembly and functional testing

The tremendous progress of automobile technology in terms of power efficiency, reduction of consumption and lower emissions, as well as increased safety, has led in recent years to the fact that a large number of automotive components are manufactured under rigorous cleanliness requirements. Technical cleanliness ensures functionality and longevity. This has meanwhile established itself as an important quality aspect in the automotive supplier industry. At the MS Powertrain Technology Group, cleaning processes are consistently and thus ecologically implemented, while defined assembly processes follow strict cleanliness requirements.

Wobbling
The wobbling method is used during assembly and storage of rocker arm rollers, for example. Wobbling, sometimes also referred to as radial riveting, is a cold forming process in which the forming force acts only on a partial surface of the workpiece. Through a wobbling motion of the upper die on a rotationally symmetrical workpiece, major reshaping can be realized with relatively little effort. The workpiece is placed in a die which fixes it from below. This die is clamped on the fixed part of a wobble press. From above, one or more rotating dies successively cold-form the workpiece. The upper die is set at a certain angle to its axis of rotation. This results in a rolling motion, during which the metal of the workpiece can flow into its new shape. Wobbling enables much larger transformations than deep drawing or simple compression. Wobbling is related to pressing, but the difference is that much more complex shapes are possible. For example, teeth or ribs can be fully formed via wobbling.

Cryogenic joining methods
The MS Powertrain Technology Group successfully uses the economically efficient cold stretching method for joining optimum press fits - as an alternative to the wobbling procedure when mounting the roller bearing. As a cryogenic joining process, cold stretching is now state of the art and represents a technically and economically interesting addition to hot stretching. The inner piece of a two-part component, designed to be oversized, is cooled down while the outer part is simultaneously heated. The inner part shrinks, while the outer section expands. In this state, the inner part can be fitted into its counterpart. Absorbing heat, the inner part expands again, and the outer part shrinks through heat dissipation, creating an optimum press fit. The cryogenic temperatures needed by the inner part for this joining process are supplied by liquid nitrogen at -196°C. Annealing colors or changes in the structure that sometimes occur during hot stretching can be prevented by cold stretching of the inner part.

Semi-automatic
Parts feed and workpiece transportation are carried out manually or semi-automatically. Semiautomatic stations guarantee an optimal balance of operating personnel and line. Torque-monitored, documented screwing stations during the assembly of camshaft housings are only a few of the many possibilities of semiautomatic assembly.

Fully-automatic
Fully automatic stations at the MS Powertrain Technology Group are equipped with automatic parts feed and guarantee fully automated assembly processes. They are designed for error-free assembly, high yield and complex processes – all of them reliably monitored and documented.

Leakage testing
To ensure that casting parts, components or subassemblies are leak-free, they are tested nondestructively on leakage test benches. This method also allows camshaft frames to be tested for leaks using air.

Continuity testing
In continuity testing, for example, the precision of internal oil drilling of rocker arms or rocker arm axes is ensured by means of laser systems.

Push-out force testing
By means of a downstream push-out force test we ensure correct design of the fit, made with several joining processes between bearing pin and rocker arm roller.

Completeness check
At the MS Powertrain Technology Group, subassemblies such as camshaft housings are checked again exhaustively at the end of the assembly process, using application-specific camera systems. Only then are they packaged and dispatched to the customer.

Unlike many other development service providers, we are certified according to DIN ISO/TS 16949 and DIN ISO 9001 as well as to DIN ISO 14001 and DIN ISO 50001. This demonstrates a high degree of structure, data security, documentation transparency and development transparency. Link to Certifications.

Since almost all our workstations are equipped with web meeting software and conference phones, an exchange in teams is also possible. Our ultra-modern meeting rooms enable integration of not only an audio but also a video conference system. This advanced equipment is the best way to guarantee the information flow.