Caulking station

Caulking station

One of the greatest challenges in vehicle manufacturing is joining drive shafts to the wheel housing. For this reason, for high-torque connections that are relevant to safety, the central nut is automatically caulked into a notch of the axle stub to guarantee a friction and form-locking connection. Moreover, the automated process has an ergonomic advantage over manual caulking with a chisel.

Automatic caulking

The caulking station is made up of the following main component groups:

  • Basic frame
  • Localisation module
  • Caulking module
  • Quality assurance module

The connection that is to be caulked is localised with mechanical or optical searching systems. The caulking chisel, which has been optimized for this task, is applied in the exact position and at the correct angle. The caulking process itself is force-stroke monitored. Depending on the technical requirements, the piece is caulked on only one side, or both.

The result is then verified with a camera system, as loose connections or caulked joints that could partially come off are a safety hazard. For traceability purposes, all data is saved.

System properties:

  • Cycle time: 60 s.
  • Caulking force: 10 kN
  • Positioning accuracy: ± 0.1 mm
  • The cutting position is found by mechanical means or with cameras

AuE caulking stations are predominantly used with high torques to securely fasten the central nut to lorry and passenger car axles (e.g. for the C-Class or E-Class models) at Daimler AG.

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