An international truck manufacturer recently challenged Delphi Stonehouse to tighten the geometric tolerances on the interface between its Electronic Unit Injectors.

Delphi is one of the world's largest automotive parts  manufacturers.  Delphi’s  Stonehouse, Gloucestershire, facility specialises in the high-precision manufacture of  Electronic Unit Injector (EUI) systems for heavy duty applications, helping vehicle and engine manufacturers around the world to meet increasingly demanding emissions legislation.

 

 

Delphi’s advanced EUI comprises an individual camshaft-plunger pump for each cylinder, that is capable of delivering fuel at very high pressures (up to 2500 bar). These high injection pressures are absolutely essential to enable engines to meet current and future emissions legislation, but require very tight manufacturing tolerances – often in the sub-micron region. In accordance with the company’s philosophy of continuous improvement, an international truck manufacturer recently challenged Delphi Stonehouse to tighten the geometric tolerances on the interface between the EUIs from 100 µm to 30 µm.

Exceeding drawing requirements, and beyond the inherent capability of the processes involved, the new increased tolerance demanded a revaluation of the manufacturing and inspection methods involved. The urgency of the request called for a rapid reaction from the customer-focused Stonehouse team. Mindful of the required quick response, a manufacturing and inspection strategy was embarked upon for the high-volume injectors. As an inspection bottle-neck was quickly identified as a major potential difficulty, in consultation with Chris Gay, one of the Delphi Stonehouse’s preferred inspection equipment suppliers; several potential gauging solutions were explored. Dedicated fixtures were seen as too inflexible. The solution was found in the  Axiom Too coordinate measuring machine (CMM) from Aberlink.  

Will Johnson, Delphi Stonehouse quality manager, takes up the story. “Having rejected several other measurement strategies, the in-depth understanding of our complex and tight-tolerance measuring problem, shown by Aberlink, on our initial approach to them, gave us the confidence to explore their suggested solution. Within a two week period, working closely with Delphi personnel, Aberlink ran injector measurement trials, made minor modifications to their software, successfully completed arduous R&R trials and installed two Axiom Too CNC CMMs within the Stonehouse facility.

Due to the  urgency of our requirements (and to further expedite the procurement process), we took advantage of Aberlink’s Lease Hire Scheme. As the Aberlink operator interface is relatively simple, we have been able to reduce training time, whilst the high speed of our new Aberlink CMMs will enable us to keep up with the current, unit inspection volume of 2000 units per week. It will also allow us to inspect our projected throughput of 3000 units.”
www.aberlink.com

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