New techniques are needed to reach the assembly demands of the ever increasing part complexities and quality requirements in manufacturing today. One of these techniques is to gauge and make in the same station. This technique incorporates the gauging and assembly into a simultaneous or sequenced process that is performed in a single station. The gauged values are used as feedback to control the assembly process.

“Press and Gauge” Station Design Considerations:
1. Design the station as a gauging station that also assembles the part. This station must pass a gauge R and R. Assemblies will only be as good as the station can measure.

2. The station must be able to measure the part with the press retracted off the part. During the process it will be required for the press to retract at least far enough off the part to allow the measurements to be taken with the part under little or no load.

3. Ensure that the station design allows for the re-fixturing of assembled parts. This allows for station Mastering, Gauge R and R studies and process debug and verification.

4. Last and maybe most importantly the part must be fixtured and measured in station identical to how it is fixtured and measured in the off line gauge. This helps to provide consistency and correlation between the stations measurements and the external gauge used for process verification.

Gauge and Make Example Application
Assembly of the isolator bushings into the upper and lower control arms used in the automobile and truck industry.

Problem:
The specification calls for a total tolerance of ±0.6mm on the bushing position. This tolerance must be held despite the fact that the bushings themselves have a ±2.0mm tolerance. How do you make an assembly to a tolerance three times tighter then the stack up of the tolerances of the parts to be assembled?

Solution:
Using a gauge and make strategy, position transducers are built into the fixturing /tooling of the station to measure the assembly as it is being made, compensating for variations in the individual parts, making an assembly within tolerance every time. The Servo Press system functions as both a press and a gauge. It measures while it makes the assembly. It does both functions simultaneously and stores the information for later analysis.

For further information, please contact Promess Sales Department at 810-229-9334 or sales@promessinc.com.