Engine Oil Pump Production Testing - CASE STUDY
Who we worked with
ATA was awarded a project from an existing client to build test systems for production verification testing on six different engine oil pump models. We delivered on the client's needs for an accurate and interchangeable tool to verify pump performance and functionality using a grouping layout for the individual test cells, and by employing laser marking stations. Thanks to our Section ID™ platform, we were able to reference previous applications and accommodate to the client’s requirements.
The advanced automation and software (FloINT™) features minimized cycle time per cell and maximized operational efficiency. An automated hydraulic clamping system was used for quickly securing the pumps while controlling the amount of axial force exerted. The test system was built as an open-ended architecture to accommodate future upgrades such as additional analog and digital I/O channels.
HOW ATA tailored TESTING TO THEIR needS
After careful analysis of the six different pump models to be tested, ATA proposed a grouping layout for the four individual test cells that would result in the most flexible setup for the client.
The high degree of automation in the process design, along with the advanced software features, would guarantee that the cycle time per functional cell would be under 40 seconds for a single operator, with a minimum operational efficiency of 90%. ATA proposed a solution to satisfy the client’s requirements using the proven methodology (Section ID™) for test stand development, a high degree of system expansion capability, and a fast delivery time.
THE Key design elements
The test stand featured a vertically mounted servo motor with encoder feedback, along with an inline rotary torque sensor, which would connect to the pump under test.
Each pump model had a specific custom fixture that would hook up to the universal mounting fixture, which was fully interchangeable among the four different test stands. An automated hydraulic clamping system was used for quickly securing the pump under test to the fixture, while at the same time being able to control the amount of axial force exerted. Once these were accounted for, we were able to refer back to our Section ID™ database and build from there.
Productivity and Expandability
Mechanical locking of the pump and the proper interface to the suction and discharge ports of the pump were automated with the use of hydraulic clamps and position switches for reliable feedback. The test stand was developed as an open-ended architecture, where in addition to providing the functionality requested by the client, provisions were made in anticipation of future upgrades, such as a variety of additional analog and digital I/O channels.
Multiple test sequences were preloaded on the test stands, which when combined with the automatic safety features of the machine, allowed the operator for more unsupervised control. A single electrical and controls cabinet, as well as an HMI touch screen display, were used for all four test stands, allowing for a more centralized control scheme.
Superior Efficiency
The robust design of the test benches allowed the client to run tests 24 hours a day / 7 days a week, with minimal maintenance required. The pump loading system was designed in such a way so that the hydraulic clamps would automatically load and unload a part if it passed all required tests. The operator unclamping was required either if the pump was not secured properly, or if the pump failed a test sequence step.
The anodized aluminum extrusion with polycarbonate plastic was used to protect the operator, as well as shield the test bay from any kind of environmental contamination. Onboard system diagnostics, with automatic alarming parameters, would notify the operator of the current test execution status, or if any conditions have caused the test to be aborted.
INTERPRETING THE DATA
Each tested pump would go through the basic test sequence:
jamming, low-speed, and high-speed driving torque
inlet, outlet, and vacuum pressure
All pumps that passed the verification test would be placed by the operator in the laser marking station for engraving, prior to being place on the final assembly conveyor. The verification report is generated automatically based on test script results (pass/fail), and the integrated software is used to maintain and organize data from all four test stands. In addition to the automatic test sequence execution, a manual mode is also provided, giving the operator the ability to set parameters manually from the test software and log the selected channels.