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Compared to traditional fuel vehicles, the motor and power control system in new energy vehicles, which replaces the engine, not only involves the conveyance and tightening of a greater variety of bolts but also the assembly of more electrical components. However, this shift has brought a series of assembly technical challenges. Facing more complex on-site working conditions, there will inevitably be stricter assembly requirements.

In the face of different types of screws in the assembly process from automatic screw feeding to tightening, what innovative solutions has Danikor brought?

Challenge 1: Automatic Screw Feeding for Screws with Low LDR

Pain Point 1: In the assembly line of new energy motor and power control systems, when screws are automatically fed from the blow tube to the gun head, if the length-to-diameter ratio is small (empirical value: LDR 1.2-1.6), it is very easy for the screws to flip at the three-way intersection of the clamp.

Solution: Pairing with a swing-arm type gun head can effectively avoid screw jamming and can also additionally add a screw storage function. During the tightening process, screws can be prepared in advance, effectively improving the production cycle of the motor and power control assembly line.

Pain Point 2: When facing screws with even smaller length-to-diameter ratios (usually LDR ≤ 1.3), due to their top-heavy nature, there is a high risk of screws flipping and jamming inside the blow tube.

Solution: Adopting a screw picking method, where screws are directly picked up from the outlet of the automatic screw feeder using a suction tube. After confirming the successful pick-up with vacuum pressure detection, the screw is moved to the tightening position. This ensures stable adsorption of the screw during movement, thereby ensuring the stability of batch production.

Challenge 2: Tightening of Soft Material Threads

Pain Point: Influenced by the demand for vehicle lightweighting, the housing of motor and power control products is usually made of aluminum die-casting. When assembling screws, the soft material of the threads can lead to thread damage and tightening failure, resulting in defective products.

Solution: The servo module uses a servo motor as the power source and interacts with the tightening tool through a PLC to achieve real-time monitoring of the bit's descent speed, displacement, downforce, and torque information. This ensures that the screws are tightened properly, not only increasing the action cycle by 20% but also avoiding thread damage, bit jumping, and floating screws, ensuring the stability of product quality. Additionally, it reduces the use of pneumatic components, lowers energy consumption, and can meet the tightening needs of products with different height differences, saving customers' Z-axis movement mechanisms and achieving cost reduction and efficiency improvement.

Challenge 3: What to Do if the Screw Is Skewed Due to Hole Entry Failure

Pain Point: During the assembly and tightening process of new energy motor and power control systems, different screws may encounter the problem of hole entry failure due to unstable support, resulting in skewed screws.

Solution: The key to the gun head's support of the screw is the coaxiality of the bit, suction tube, and screw! By strictly controlling the gun head's manufacturing process and ensuring its machining accuracy, and through high-precision 3D coordinate system full-size inspection during the manufacturing process, the coaxiality is guaranteed, ensuring the verticality and stability of screw adsorption, thereby improving tightening quality. At the same time, different types of gun heads can be paired according to screws with different length-to-diameter ratios to ensure equally stable support!