Fastening Automation Systems
Fuel Tank Install System
Features:
- The fuel tank is manually loaded onto the assist and the bolts are manually loaded
- The assist tracks under the vehicle for a dynamic torqueing installation
- The fuel tank end effector manually pivots out from under the body carrier area when not in use
- A spring-loaded counter balance to support weight of fuel tank
- An electric motor, clutch, and gearbox drive with friction drive wheel returns the decking fixture home
2-Spindle Con Rod Manipulator
Features:
- 3500 Series Two-Spindle Torque Tool System
- Mechanical brakes at the two articulating arm pivots and at the pivot right above the multiple
- Proximity switches indicate which two bolts of the four bolts on the bolt pattern are being torqued to tie the torque data to each fastener
- The two spindle multiple is suspended from a turntable bearing just below the torque tube to allow the two tools to be indexed automatically and rotated about the connecting rod cap bolt circles
5-Spindle Lug Nut Secure System
Features:
- Ten FEC Electric tool and controllers are utilized
- Five tools are mounted on the individual pneumatic slides which when fed to the engage, the selected bolt circle’s retractable hex drive shafts are extended outward clear of the set of sockets not being used
- Five tools are mounted on individual links such that a common plate rotates by a pneumatic rotary actuator pivots and the five tools simultaneously interchange between the two bolt circles
7-Spindle Skid Plate Fastening System
Features:
- The end effector is designed to locate the assist off the vertical conveyor stanchions which allows the assist to be towed with the frame
- The assist’s weight and size is minimized to maximize the ergonomic benefits of the assists for the technicians
- Pneumatically actuated brakes allow the operator to lock the assist into position on the bridge and runways
- Mutilation control – Non-marring pads to prevent damage to the vehicle body
Corner Module Fastening System
Features:
- Dual 6-spindle assemblies automatically actuate down onto the RH and LH corner module assembly’s hand started bolts
- The conveyor indexes the pallets in and out of this station
Spring Compression Secure Systems
Features:
- Enhanced HMI screens to display the torque data
- Torque data from (4) subframe joints and (2) shock bolts sent to Quality PLC
- Retrieves torque data from from the tool controllers
- Eliminates (3) tool interface boxes and all associated hardware, installation, and commissioning costs
Tailgate Secure Systems
Features:
- Overhead Carriage Supported Parallelogram Articulating Arm with quick change feature to attach two different end effectors
- Articulating Arm capable of supporting different/multiple jigs, one with two tools and the other with four tools
- IV ATC style used to change tooling connection
- No park position is required, so no additional overhead rail is required
- Electric DC tools have keyed quick disconnects
- Integration of rpGatta’s Twist Grip Hoist/Balance Controller
6-Spindle Torque System
Features:
- Six-Spindle Assist cantilevered from a linear overhead rail
Robotic Fastening
Features:
- Automatic bowl feeding of bolts
- Bolts are pneumatically blow-fed to the robot end effector
Resolver Cover Multi-Spindle
Features:
- Interfaces with a part that indexes in on top of a conveyor
Knuckle Torque System
Features:
- 2-spindle assembly automatically actuates down onto the RH and LH knuckle hand started bolts
- The dial table indexes the knuckles in and out of this station
Multi-Spindle Manipulator
Features:
- Adjustable jack bolt joints allow the manipulator arm to be leveled to allow a perfect balance mode of the end effector
- Pneumatic brakes disks on the manipulator joints engage when the multi-spindle is on the bolt heads
EV Battery Decking and Auto Fastening
Features:
- rpGatta's custom designed electric vehicle battery installation system is capable of semi-automatically lifting and fastening the heaviest modern batteries:
- System automatically conveys battery on a pallet into in lifting fixture and centers the battery
- An operator places bolts into the electric torque tools
- The heavy duty electric motor driven lift raises the battery to the under side of the vehicle and locates the battery and fasteners automatically
- Torque specifications are verified and sent to quality database on plant network
- Our decades of automated fastening experience yields robust and highly reliable fastening systems
- PLC Controls, HMI, and Safety Programmable Laser Scanners ensure maximum safety and equipment uptime
Rear Suspension Fastening/ Compression System
Features:
- Rear suspension mount equipment utilizes a servo motor and chain powered system for lifting the rear suspension to the body and compressing the springs
- Capable of lifting 70 kg of parts and compressing the suspension with 365 kg of force
- Heavy-duty cam follower slides will guide the vertical motion of the lifter as it raises into position
- Safety bellows surround the lifting mechanism to ensure safety
- Fixtures manually rotate back under the vehicle and lock into position
- Safety bump switches activate caliper brakes to safely stop the powered motion in the event that someone or something is in the path of travel
- A pneumatically actuated centering slide and pivot arrangement allows the suspension to line up with the body and accommodate for variances in the body location in the overhead carrier yet return to a nominal center position
- Two handed anti-tie down push buttons for cycle start
Rail Torque Table
Features:
- Table with 4-bar linkage weldments for zero-gravity manual torque tool support
Con Rod Disassembly System
Features:
- Connecting Rod Disassembly Machine is robotically tended
- Connecting Rods are loaded into the machine fully assembled and the fasteners are loosened with DC electric nutrunners
- Torque is monitored when each fastener is removed to ensure that the fasteners were at the proper torque during the machining process in the previous operation, improperly torqued fasteners would result in an “out of round” connecting rod
- Once the fasteners are loosened, they are removed from the Connecting Rod and dropped onto conveyors where they are accumulated in baskets outside of the cell
- After the fasteners are removed, the Connecting Rod and Cap are robotically removed from the machine and the next Rod is loaded in
10-Spindle Skid Plate Fastening System
Features:
- The Ten Spindle Carriage keeps track of tool position throughout the tightening process utilizing laser encoders
- The system control is achieved by utilizing ergonomically positioned thumb joysticks and operator pushbuttons
- The control system incorporates error proofing the process of torqueing the head so that all bolts are properly tightened only once
- Practical Intelligent Assist Device (PIAD), U.S. Patent #7,461,753B1
- No proprietary “black box” controls
- Utilizes standard controls that meet your plant specifications, thus your maintenance department will be very familiar with these control components
- Enhanced positioning and travel capabilities
- X, Y, Z variable speed thumb joystick control to allow operator to feather end effector into position
- Can adjust from coarse to fine movement
- Safety Features
- Unit has an optical two-hand anti-tie down built into handles
- Brake arrangement locks PIAD in position when not in use
- Ease of Use and Maintenance
- Motion is controlled by joysticks that remain oriented to direction of travel regardless of unit rotation
- Diagnostics and maintenance are accessible via a standard touch screen display
- No proprietary “black box” controls