Leak test + screwdriving station for aluminum monoblock — 3 cavities, 3 pressures
Lübeck Automation's inaugural project — the transition from distribution and service to systems integration. Canadian OEM was launching a new line for an aluminum monoblock with three connected internal cavities, each with a different leak rate and a different test pressure.
Three cavities, three pressures, one cycle — no interference, no false rejects
Canadian OEM was launching a new production line for an aluminum monoblock with three connected internal cavities. Each cavity has a different leak rate and a different test pressure. Cavities 1 and 2 are isolated by a plug that is screwed in at the start of the process; cavities 2 and 3 are separated by an internal expanding seal.
The upper and lower sealing areas are extensive. Sealing with pneumatics meant a Ø160 mm actuator or larger (high air consumption, oversized tank) or a Ø100 mm with robust pneumatic brakes on each post (more expensive). Any seal float during measurement alters the test volume.
Hybrid architecture: hydraulic for sealing, CKD for the rest
Lübeck designed a hybrid sealing architecture. For the main sealing, a press-type hydraulic system was chosen that guarantees parallelism and service life. CKD pneumatics for the rest of the system. Dimensioned under ASME Y14.5 (GD&T) with safety factor greater than 2.
Press-type hydraulic sealing
Floating plate guided at 4 corners with packed double-sleeve bushings with center flange. Ø40 mm hard chrome guide bars. Ground bottom plate with flatness and parallelism tolerances.
5/3 closed-center solenoid valves
Against pressure fluctuations or emergency stop, actuators hold position: zero float during measurement. CKD pneumatics in the rest of the system.
CTS LPC 528 with per-cavity program
High-hermeticity valve circuit admits air only to the cavity under test. Calibrated leak masters matched to each cavity's specification. Independent auto-calibration as an additional PLC sequence.
Silicone seals 60 Shore A
First supplier delivered vulcanized seals too hard — they didn't seal. Second supplier with the same spec in 60 Shore A silicone: worked on the first try. Dimensioned under ASME Y14.5 with safety factor >2.
25% margin over takt time — and Lübeck's DNA built along the way
"The company acquired its engineering DNA at the same time it delivered the cell."
— Portfolio documentation, case 01
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