Case Studies

Rocker Cover

Rocker Cover

 

Rocker Cover

Overview

Project Rocker Cover
Timeline April 2017 - March 2017
Direct Customer Parker Racor
OEM JCB
Volume 40,000 units per annum with potential to increase to 80,000
Key Project Partners Engel UK - Injection Moulding Machine
  ABI – Toolmaker
  BASF - Raw Material Supplier
  Southfork Innovation – Welding, Heat Staking and Assembly Fixtures
  Harrison Silverdale - Metal Inserts
  Carbis – Filter Mesh

Specifications

Scope Rocker Cover with integrated breather system, valves and fixings
Complexity 7 Injections Mould Tools
  Compression Limiters / Threaded Inserts / Wire Filter Mesh / Umbrella Valves
Technology Injection moulding
  In-Line Assembly
  Ultrasonic Heat Staking
  Spin Welding
  In Process Vision Testing
  Pressure Decay & Vacuum Testing
Challenges Flatness Prediction
  Tool Compension for Flatness
  Tooling Complexity
  Distortion Control
  Dimensional Tolerances
  New Technology Integration
  Challenging Lead Time
  Joining Welding
  Automation
  In Process Verication

Construction

Rocker Cover Construction
Rocker Cover Flatness Testing

Moldflow Results

Moldflow Results

Tooling Complexity

Tooling Complexity
  • Profiled Split Line
  • Ampcoloy Inserts to reduce heat in difficult to cool areas
  • Textures A-Surfaced Finish to JCB Specification
Tooling Complexity

Lower Sump Assembly

Heat and Vacuun Test
  • Heat Stake & Vaccum Test
Inspection
  • 100% Inspection of all assembly items to ensure presence and function with pass / fail
Vacuum Pull Test
  • A vacuum pull test is caried on the Vernay Valve

Jet Pump Assembly

100% Check of Leak with part verification

Heat and Vacuun Test
  • Spin Weld
Inspection
  • Leak Test with 100% marking of passed parts
Vacuum Pull Test
  • Compression Limiter Assy
Vacuum Pull Test
  • Completed Part

Rocker Cover Assembly

Rocker Cover Assembly
  • Assembly of Compression Limiters with 100% presence check.
  • Sensors on each Compression Limiter (x10). Assembly will not commence without.

Completed Part

Completed Part

End Result

End Result

 

End Result

Outcome:

Project scope satisfied, launched on-time, within budget and to customers full satisfaction.