All Parts Filed Under Automotive
A Dual Opposed Solution
When backing out of your driveway and speeding down the road on your way to work, you probably don’t give much thought to the effort it takes to run your vehicle. We have come to expect the highest quality out of our vehicles to provide transportation, while keeping us safe. Vehicle manufacturers perform stringent tests to ensure the highest quality, giving you a smooth, worry-free ride.
Orbitform upholds the same quality standards with fastening, forming, riveting and assembly, so it is no surprise that we were approached to find a self-contained solution to form carrier pins in a transmission planetary carrier gear. In a completed assembly, components were held in place by either four or six carrier pins. A machine solution was required to form both sizes of gears and to form the carrier pins equally on each side to meet the high-quality standards.
Upon review of the assembly, the largest challenge was with the tolerancing of the carrier pins. Prior to forming, the pins were slip fit, held in place by grease. While forming the first pin, the other pins could fall out due to the slip fit. Orbitform partnered with the manufacturer to design a fixture that would allow for robotic loading and unloading and hold all pins in place during the forming process. The fixture could also shuttle to hit the next pin, thus creating a self-contained solution.
The next challenge addressed was the forming of the pins. During testing in Orbitform’s Solutions Lab, our lab technicians found that orbitally forming the pins .070” on each side created the desired form to withstand the pushout forces the carrier would be seeing. However, the pins required a back-up upon forming.
A Dual Opposed Solution
To combat these challenges and meet the required cycle time, Orbitform introduced the idea of a dual-opposed system that was programmable to run either the four pin or six pin carrier. An orbital powerhead would act as a hard stop on one side of the carrier pin while the other side was being orbitally formed. Next the two powerheads would switch jobs and form the opposite side. After this cycle was complete, the fixture would then shuttle to the next pin and begin again.
In developing this dual opposed, self-contained system, Orbitform was able to provide a solution that exceeded expectations and achieved the required cycle time. In addition, through partnering with our customer on this project, Orbitform was able to ensure the carrier pins overperformed in safety tests to provide the highest quality vehicle components possible.
Orbitform is committed to providing high quality, robust and unique solutions to overperform in meeting the functional requirements in a joint. Afterall, on your drive home from work tonight, your thoughts should be on your family, not questioning the safety of your vehicle.
Orbitform stands ready to partner with you on your next fastening, forming, riveting or assembly project. Contact us today to find your unique solution.
Industry Spotlight: Automotive Parts
Orbitform has worked with many industries, including medical, aerospace, recreational, and more. As a proud Michigan manufacturer, we have been partnering with automotive manufacturers for 30+ years. We have provided assembly solutions for a large variety of automotive applications, including seating components, strikers, and more. Here are a few examples of some of the components found in your vehicle that we have provided equipment to assemble.
Orbitform has provided numerous assembly solutions for seating applications in vehicles. Recliner mechanisms require smooth articulating joints for seamless movement. Orbital riveting uses less force then pressing which minimizes the shank swell of the rivet and allows for articulation. We have also provided orbital riveting equipment to assemble the folding seat assembly found in many cars. A more unique seating component that Orbitform has provided equipment for is the seat belt spool retractor. Our articulating roller forming process forms from the side. We used this to access the forming location under a preexisting lip on the seat belt spool retractor.
Striker wires are used in multiple locations inside a vehicle, including trunks, doors, and seats. Depending on the hardness of the wire, either the hot upset process or orbital riveting process can be used. For the seat back striker, we provided orbital riveting because it required less force and more control for the final form diameter. For harder materials and higher strength requirements, we have used our hot upset forming process. This applies heat and force simultaneously to form a strong joint. Orbitform has even automated this process to meet production volume requirements of striker wires for automotive applications.
Other Automotive Applications
Window regulator rail assemblies use a small pulley system to roll your car windows up and down. Orbitform has provided orbital riveting systems to form the pin holding those pulleys in place, allowing them to freely rotate. Orbital riveting equipment can also be used for non-articulating joints, such as securing baffle plates inside a front engine cover. Our roller forming equipment has been used to roll over the edge of an oil gauge to retain the inner components.
With 30+ years of experience, Orbitform has worked with many manufacturers across multiple industries. Our assembly experts have assisted on a wide variety of assembly applications, including the few mentioned above. Contact us today to discuss your applications and learn how we can help improve your process.
Orbital - Captured Form
Captured Form on Solid Rivet
A peen with a cavity keeps the formed material from spreading out, giving an ascetically pleasing form that is less likely to display cracking around the edges. Note that a captured for requires more force than a flat form.
Die Cast Aluminum
An automotive parts supplier needed to permanently retain a sound deadening baffle plate on the inside of an engine cover. Extensive testing in Orbitform's Solutions Lab led our engineers to develop precision rivet geometry, rivet coatings, and forming forces to create a cheaper and more reliable process.
Process: Semi-Tubular RivetsMultiple rivets were set with a single impact machine using an X-Y table, increasing efficiency. Process monitoring provided quality control, while multiple part fixtures for the same machine increased versatility and Return on Investment.
Extruded Lip and Gear
When spot-welding failed, an automotive parts supplier contacted Orbitform to attach a hardened steel gear to a metal stamping. Orbitform engineers suggested adding an extrusion and orbitally forming the extruded lip over the gear, eliminating the need for a costly fastener.