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The powertrain system, as the most important and complex component in a vehicle, is akin to the heart of the human body—it is the "energy source" that continuously delivers power. Faced with the rapidly growing demands for automation, intelligence, and flexibility in powertrain production, as well as the complex requirements for bolt tightening and assembly, is there a solution that can meet both challenges effectively?

In powertrain assembly lines, 50% of the workstations are related to the automatic feeding and tightening of bolts. Given the characteristics of large bolt specifications, numerous long bolts, tight space for tightening positions, and low product positioning accuracy, Danikor has precisely targeted these assembly challenges, aiming to automatically feed every bolt into position to ensure efficient and consistently high-quality assembly.

Challenge 1: Large Bolt Specifications and Numerous Long Bolts

Bolts used in automotive engines have large specifications, with the largest being M24 and bolt lengths (threaded section) reaching up to 225 mm. These are challenging to blow-feed in automated workstations, especially when affected by workstation layout and long blow-feed distances.

Solution: A stepwise screw feeder is used to automatically feed screws ranging from M0.5 to M24. A lifting nail separator is employed to achieve automatic feeding of long bolts, and a gripper module is used to pick up the long bolts, stably supporting them into the holes to prevent dropping.

Challenge 2: Low Product Positioning Accuracy

Due to fixture positioning deviations and manufacturing accuracy of the product housing, there are errors in bolt hole positioning. Traditional solutions using 2D camera positioning and recognition have spatial angle deviations. Moreover, camera imaging not only affects the production cycle and space layout but also has long debugging cycles and high hardware costs.

Solution: The external hexagonal blow-and-suck sleeve floating technology is adopted, with multi-directional floating capabilities that can accommodate certain positioning deviations (0.5-2.5 mm). This significantly improves the hole entry rate and tightening success rate while being more cost-effective and efficient.

Additionally, for complex tightening conditions such as flat surfaces, single-sided interference, variable interference, and countersunk hole interference, different types of tightening modules are introduced to ensure that the gun head can smoothly drive the bolt into the hole without obstruction during tightening.

Challenge 3: Tight Space for Bolt Positions

With a large number of fixing bolts on the engine housing and limited space, the spatial layout requirements for multi-axis tightening mechanisms are very high. Traditional tightening mechanisms are complex in structure and occupy a large space.

Solution: An integrated multi-axis tightening module is used, which can currently achieve synchronous tightening of up to 12 tightening axes. Compared to traditional mechanisms, this module is lighter and more compact. Additionally, with no external moving parts and fixed cables, it is more suitable for integration with robots, especially for the installation layout in tight spaces, enabling the tightening of bolts with smaller spacing.

Challenge 4: Feeding of Easily Deformable Materials Such as Seals

In addition to the challenges of bolt feeding and tightening, the engine assembly process also involves the feeding of rubber seals. Due to their soft material, traditional vibratory feeders can easily deform them, causing stacking and tangling that affects the feeding cycle.

Solution: A flexible feeding system is used, which can easily disperse the material by adjusting the amplitude and frequency. A combination of a lifting hopper and a straight vibration hopper is employed for feeding. The lifting hopper disperses the material upward at an angle, reducing stacking, while the straight vibration hopper provides stable feeding speed.