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Production of airbag detonator caps
Mikron assembling production line
Mikron Automation is one of the leading manufacturers of high-performance automation solutions for high-precision assembly and testing.
Mikron has implemented a production line for airbag detonator caps for a customer in the automotive sector. Such an ignition capsule consists of the
outer primer cap, which is filled with black powder, and the inner cylindrical body with electrical connections.
Together with Parkem, Mikron has developed a high-precision servopress in the ATEX area for pressing in black powder and integrated it into the existing system process. The flexiPRESS consists of an ATEX-certified GSM electric actuator with integrated servo motor and force sensor as well as the comPRESS force measurement control system. This servopress replaces an initially planned pneumatic solution, which produced too many rejects due to inadequate force and position control. Not only is the maximum press-in force defined and monitored, but also the speed profile and the force during placement and pressing. All measured values such as force, position etc. are read out and stored for quality assurance and process monitoring.
The flexiRESS control system is designed as a self-contained system and provides various integrated functions which are called up by the higher-level control system via Profinet. After the start command, the press moves
quickly moves to a predefined reference and checks the force applied. If this rises to an unacceptably high level, the process is aborted and the press moves to the park position. If not, the speed is reduced from the reference mark, as the press can now hit the detonator at any time.
As the increase in force up to 2000N takes place within a few tenths of a millimeter and force overshoot is not permitted, the travel profile is calculated and adjusted cyclically every 0.5ms (!) using a fast task based on the actual force. If the defined force is reached, the press stops and the current position and the current force value are saved and logged. An evaluation is made as to whether the pressing process was within tolerance or not. At the same time, the drive moves back to the park position. The entire cycle takes 800ms. Mikron Automation has so far integrated 22 flexiPRESS systems for its customers.
