Automated Machining Cell for Automotive Shaft Production

To accommodate mass production at the rate of 2.5 mil units annually, at Glueckler Metal Inc., we engineered a custom manufacturing work cell for end-to-end automated production of the automotive engine shaft shown here.

Problem:

This alloy 1117 steel shaft measures 1.580" OD x 1.300" in length and requires critical tolerances of ±.00039" (±.010 mm) to ensure a precise fit and rotational balance in the final shaft assembly. With our previous experience, engineering capabilities, and industry qualifications, we were offered the opportunity to acquire the program for this part from an underperforming competitor. Our challenge was to develop a system for repeatable manufacturing of conforming product in high volume.

Solution:

Our approach involved capturing all elements of the manufacturing and measurement processes in a dedicated production cell and leveraging statistical/data based control to minimize scrap and defects. The system incorporates ten different machines to perform CNC machining, multiple inspection processes, serialization, and custom packaging. Along with integrated SCARA robotics and custom software to control part monitoring and transport, highlights of the system include part measurement with automated feedback, a custom designed thread check station, and a high-performance CMM with feedback control. This cell also incorporates 100% air gauging, an eddy current crack detection system, and a custom packaging and tray system.

This cell operates 24/7. With features such as feedback systems, centralized coolant and scrap recovery, and automated part orientation, tracking, and packaging, it requires minimal hands-on intervention, and our onsite maintenance department ensures maximum uptime. Periodic inspection line checks followed by dock audits and final certification were performed to ensure the system continued to run smoothly.

Results

In addition to attaining a long-term contract with high volume production requirements to date, we are involved in new product and generational design projects for this customer.

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Automated Machining Cell Specifications