Messy production processes lead to frustration, downtime, material waste, increased costs, and reduced production capacity. A systems integrator approached GP Reeves for a solution to an inefficient RTV application process. The company was attempting to apply RTV material to the transaxle housing used in John Deere tractors and XUVs. These vehicles provide operators with dependable means to efficiently clear land, manage livestock, cultivate crops, and complete harvests. While these machines are built for tough jobs, their assembly processes should remain clean and streamlined.
The Problem: Messy and Inconsistent Application
Initially, the integrator employed a time-pressure system with a luer lock tip to dispense the RTV material. However, this system encountered several challenges, including speed limitations, inconsistent volumes, and susceptibility to variations in viscosity and temperature. Additionally, the luer lock tip was not zero-cavity, which allowed for material oozing and wastage. These issues were further compounded by the characteristics of the RTV material itself. RTV, a type of rubber that cures and hardens when exposed to room temperature, became problematic when processed through the inadequate time-pressure system and luer lock valves, leading to material curing inside the machinery and causing clogs.
Addressing these clogs required significant labor, cost, and time, often resulting in inaccurate bead dispensing. The time-pressure system also allowed air to enter the cavities of its parts and nozzles, causing gaps in the RTV material as it was applied to the transaxle surface. Faced with excessive waste, escalating costs, and frequent disruptions to the production line, the integrator turned to GP Reeves for a more effective solution to this recurring issue.
The Challenge: Applying a Unique Material with Customized Conformity
Materials that ensure a machine’s durability and reliability are essential in the development of transaxle components for tractors and XUV systems. For example, a transaxle includes a housing cover that is bolted directly onto the transaxle housing, enclosing oil that must be securely contained. RTV, with its durable yet flexible bond, is the optimal solution to prevent leakage. It withstands the mechanical stress and environmental exposure that transaxle components typically endure.
However, working with RTV presents challenges in the manufacturing process. The material cures and hardens when exposed to moisture in the atmosphere or a room-temperature environment, necessitating careful handling and proper maintenance. Additionally, RTV is prone to air bubbles; exposure to air can create gaps in the material flow and dispensed product. As such, this unique and complex material must be managed with precision and attention to detail. To ensure successful RTV dispensing, the machinery components must be designed to accommodate the specific needs and requirements of the integrator’s preferred RTV product.
The Solution: Automated System from GP Reeves
GP Reeves developed a comprehensive solution to address the integrator’s challenges with RTV application. Our engineers resolved the key issues of inaccuracy, premature curing, and high maintenance costs by implementing our advanced dispensing systems. First, we incorporated our patented air check compression test, which effectively eliminated inaccuracies caused by air presence. By monitoring and controlling air levels, the RTV material no longer experienced gaps, ensuring consistent and accurate material bead lines.
Our automated dispensing machinery provided repeatable precision, guaranteeing that flow, volume, position, and pressure remained consistent across all dispenses. As a result, uniformity in material beads was achieved, allowing operators to rely on the system’s performance without concerns over dispensing errors or the need for excessive clean-up.
To address the issue of premature curing, GP Reeves implemented zero-cavity dispense valves, preventing the RTV material from coming into contact with moisture or room-temperature conditions before its intended dispense time. The system utilized the AA7 dispenser, specifically designed to handle materials with moisture-curing properties. Additionally, the air-operated pump with a single-post ram, featuring an inductor seal, ensured precise material maintenance. Our attention to detail and technical expertise ensured that both the RTV material and its curing characteristics were meticulously managed throughout the dispensing process.
GP Reeves successfully addressed the issue of premature curing by utilizing zero-cavity dispense valves, which effectively prevented the RTV material from coming into contact with moisture or room-temperature conditions before its designated dispense time. The system employed the AA7 dispenser, specifically designed to handle materials with moisture-curing properties. Additionally, the air-operated pump, equipped with a single-post ram and inductor seal, ensured precise and controlled material management. Our meticulous attention to detail, combined with years of expertise, guaranteed that the RTV material and its curing characteristics were expertly managed throughout the dispensing process.
GP Reeves significantly reduced the maintenance required for the dispensing process with its innovative technologies. Our zero-cavity dispense valves eliminated issues with oozing material, freeing operators from the burden of frequent clean-up. The servo dispenser we implemented ensured precise and consistent dispensing, resulting in uniform bead widths and positions. This enhanced the efficiency of the transaxle assembly process, allowing assemblers to work with confidence, free from concerns about inaccuracies.
Additionally, the automated dispense system was designed to adjust the rate of dispense based on the location and timing, enabling seamless application of RTV material around various positions of the housing structure without manual intervention. Ultimately, our clean, accurate, and reliable automated system drastically reduced the integrator’s downtime and maintenance requirements, optimizing overall production efficiency.
End Results: Reliable Repeatability
By integrating an automated dispensing system from GP Reeves into their assembly line, the integrator was able to significantly accelerate the production of transaxle housings, key components used in robust farming vehicles worldwide. This streamlined process not only improved operational efficiency but also enhanced sustainability and productivity across the assembly line. The financial impact was equally impressive, with substantial savings in maintenance, labor, and material waste.
Our advanced dispensing machinery optimized the production process, enabling the integrator to achieve a level of speed and quality that was previously unattainable. At GP Reeves, we are dedicated to driving your business towards success, and this project exemplifies our commitment to delivering innovative solutions. Discover how our technology can transform your assembly line and help you meet your business objectives. Connect with us today!
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