With the increasing complexity of the components of the powertrain components and the decreasing total number of mass productions, the production of powertrains inevitably encounters many processing problems and technical problems. Due to its special processing technology, hot-sleeve technology can cope with and solve many production needs and problems in this field. For example, the installation of cams or gears on the shaft by hot-sleeve technology can significantly reduce the weight of the components while ensuring higher precision of the shaft components and the production of workpieces requiring high torque and high dynamic loads. After years of hard work, the experts of the automation company of the EMAG Group have developed a patented hot-sleeve technology that provides a unique flexible processing solution for the production of automotive powertrains.
The production of powertrains requires the flexibility and efficiency of their processing equipment. In general, to meet the diversity of camshafts and gear shafts with complex geometries, different batches can only be produced in the same position; on the other hand, the market demands for finished components are getting higher and higher. Such as the selection of high-strength materials, the complexity of the structure, the reduction of volume and the lighter weight. Combined camshafts are easier to meet market demands due to their simple machining concept. Taking the automotive industry as an example, firstly, various independent cams and shafts are mass-produced, and then assembled according to the type of engine. The use of a combined camshaft not only significantly reduces production costs, but also guarantees high accuracy.
Potential huge economic benefits
The EMAG hot patented technology was developed by experts from the automation company of the EMAG Group, which is headquartered in Hoibach, near Allen, Germany. The hot-sleeve technology is mainly used to produce high-precision parts - especially combined camshafts - and the process can be completed without any resistance. At the heart of the technology is the ability to accurately reach the desired temperature through induction or contact heating. The associated preheating device is a built-in temperature control component that conforms to the geometry and characteristics of the workpiece.
VA 700 T - Equipment for the manufacture of modular camshafts. When the previous cam is hot set, the next one is already warming up. The hot-sleeve machine with a certain number of preheating devices enables the hot-sleeve technology to be effectively used in production tasks.
Thereafter, the preheated workpiece is combined with the shaft without any external force, and the workpiece is tightly attached to the shaft after being cooled. With the perfect combination of robotics, CNC axes and clamping technology, the thermal jacket technology limits the error to within 15 microns. Moreover, the entire process of producing the camshaft, from picking up the relevant components to completing the hot sleeve machining, takes a total of only 7 seconds. Therefore, the entire production process of a 4-cylinder engine using a combined camshaft assembly takes only about 40 seconds. In the EMAG hot-sleeve processing system, when the previous cam is hot-sleeve, the next one is already preheating, which greatly increases the production speed of the process.
The assembled gear shafts combine the robot with special clamping technology to achieve an error of less than 15 microns.
This process not only greatly shortens the production cycle, but also provides a high degree of freedom for machine configuration. For example, hot-sleeve machining can be performed on many different materials, such as forged cams, and there is no need to perform a finishing process after combination. To this end, users can choose to use more cost-effective materials to reduce production costs when producing components such as plugs or end pieces. EMAG hot-sleeve technology not only meets the individual needs of each component, but also improves its precision, which will have a positive impact on technology development and product functionality. For example, incorporate more new and different designs into the smallest space.
The camshaft is formed by a hot sleeve. The high-precision combined camshaft greatly reduces the need for fine grinding, and even with precision finished cams, even fine grinding is not required at all.
Tailored system design
What special manufacturing techniques are needed for the hot-sleeve process equipment? First of all, it is important to note that the process must ensure an accurate production sequence - preheating, hot jacketing, and then cooling. Moreover, EMAG experts have all the expertise of process integration systems, tailored to different production solutions tailored to specific production needs.
Therefore, those machinery manufacturers from the industrial centers in southern Germany are very optimistic about the economic potential of the technology itself, and are also optimistic about this. In particular, with the gradual rise of emerging markets in Asia, the total amount of motor vehicle production has increased rapidly, and more and more suppliers will inevitably need to increase productivity in the next few years. The hot-sleeve technology developed by EMAG Automation is a future-oriented technology solution that fully meets the needs of future technological developments. For example, the advanced engine equipment used in many multi-purpose vehicles is now a combination of camshafts with integrated bearing components. From one side, we can clearly see the importance of hot-sleeve technology in the industry.
EMAG hot-sleeve technology can be directly processed by precision finished cams, so there is no need to carry out subsequent finishing grinding of these shaft parts, thus avoiding the debris generated by the bearing, which is why the combined camshaft has Unique features. I believe that this process will become increasingly important in the design of multi-purpose vehicles in the future.
The process is equally applicable to the production of gear shafts. The heat sleeve of the gear and the shaft ensures a compact design of the gear shaft and a high functional density, and the gear can fit the shaft step surface.
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