Cover-Gear Box assembly

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Presentation transcript:

Cover-Gear Box assembly

Terms used Cover (plastic) Gear Box (aluminum)

Aim of the study Check the good alignment of the cover on the gear box permitting to insert the 4 screws that seal the both parts together. Sometimes on the line it is impossible to assemble the 2 parts because the 4 holes are not aligned. The cover hide the gear box hole  the screw can’t enter. Good part Bad part There is a gap between the blue circle (cover) and the red one (screw on the gear box)

Assembly process First the gear box is placed on the tool fixture by 3 pins matching in 3 holes on the gearbox. This operation doesn’t have any influence on the measurement required… The operator place the cover by hand on the gear box using 2 pins and a surface as a stopper. Surface Pins There is a seal on the Cover surface but not used in the simulation

Assembly process Then when the cover seal touch the gear box stopper surface, the 4 screws go down and are assembled at the same time. Pin 1 Mounting Points Pin 2

My modeling First move (gear box to tool)  no influence Second move (cover to gear box) I used a Step plane move aligning first the sealing surface as 1st locator. The others points used are in the model. The hole-pin floats have been switched on. I put a iterative logic condition in order to simulate the fact that if ever at the first shot the 4 mounting points are not aligned it is possible to remove the cover in order to find a correct positioning. That what happens in reality : the screwdriver will make the cover move on the gear box thanks to the hole pin floating until a assembly position would be found. The measurement I made is a circle interference between half circle of the cover mounting points and the 4mm screw I supposed already in the gear box. The min limit is 0 as I don’t want any interference between the screw and the cover hole.

My modeling All the tolerances are in the model.  true position of the various mounting points  size tolerance of the holes/pin  flatness of the surface Do you see any incoherence in the model ? Does it match with the process description I made to you ? Any advice/improvement we could do ? Thanks !