Tired of High Defect Rates in Camshaft Bushing Assembly? You're Not Alone.

Camshaft bushing installation plays a critical role in engine performance, directly impacting NVH (Noise, Vibration, and Harshness) and product longevity. Yet, many manufacturers still rely on outdated hydraulic or pneumatic systems, facing challenges like:

• Low first-pass yield

• Inability to handle mixed-model production efficiently

• Lack of real-time quality traceability

This article shares five real-world solutions from OEMs and Tier-1 suppliers who replaced their traditional press systems with XIRO electric servo presses—achieving near-zero defects, 20x faster changeovers, and full digital traceability.

Camshaft (Bushing Assembly)

（For confidentiality purposes, the product images shown are representative illustrations only and do not depict actual client-specific product）

Case 1: Fixing Coaxiality Deviation in Camshaft Sleeve Installation

Challenge:

A engine plant experienced >0.1mm misalignment while press-fitting Ø32mm camshaft sleeves, causing engine idle noise to exceed 72dB.

XIRO Solution:

1. Closed-loop control with piezoelectric sensors (resolution: 1/10,000 FS) achieves force control accuracy of ±0.5% FS (ISO 13849-1 certified).

2. 6-axis force sensor + optical grating encoder for real-time X/Y/Z deviation detection and auto-correction of press head alignment.

3. Segmented pressure gradient control:

• Pre-pressing: 5kN force for angular calibration (0.5s), eliminating assembly gaps.

• Main pressing: 80kN force with 0.05mm/s speed to minimize material springback.

• Precision pressing: 30kN hold for 3s; laser measurement ensures ±0.03mm depth accuracy with springback compensation.

Camshaft Bushing Press-fit Curve

(Data source: XIRO)

Result:

Coaxial deviation reduced to<0.03mm (SAE J244 Class A); yield increased to 99.98%.

Case 2: Adapting to Soft Materials Like Aluminum Cylinder Blocks

Challenge:

A new energy vehicle maker faced deformation when press-fitting steel bushings into aluminum (HB60) blocks due to strength mismatches (Al: 150–350 MPa vs. Steel: ≥600 MPa).

XIRO Solution:

1. Real-time stiffness detection using 32-bit motion controller (2,000Hz sampling).

2. Dynamic curve adjustment based on material database and stiffness feedback:

• Initial contact: 20kN/s slope.

• Plastic deformation: auto-switch to 5kN/s for aluminum compliance.

3. Feed-forward compensation preloads control values from cam sleeve stress-strain curve to eliminate mechanical gaps.

Result:

Roundness error dropped from 0.15mm to 0.03mm(better than ISO 1101); CPK improved from 0.89 to 1.78; annual scrap reduced by 97%, saving $120,000/year.

Case 3: Eliminating Scratches on DLC-Coated Bushings

Challenge:

A Japanese Tier-1 supplier experienced 5% scratch rate on Ra 0.2μm DLC bushings, with each defective unit costing $120.

XIRO Solution:

1. Precision guidance + anti-vibration system:

• Air bearings + silicon nitride ceramic bushings (μ = 0.08).

• Active damping (>5Hz, amplitude<0.02μm).

• Combined for submicron-level motion accuracy.

2. Current-Speed-Force coordinated control:

• Torque ripple<0.5%.

• Speed error <±0.1mm/s.

• Force feedback via piezo sensors to ±3N with instant shutdown on out-of-tolerance.

Result:

Friction torque SD cut from 15N·m to 2.1N·m; coating damage rate dropped to 0.05%—400,000 parts defect-free; $850,000 annual savings.

Case 4: Achieving 90-Second Changeovers in Mixed-Model Production

Challenge:

A U.S.-based line handling 12 bushing types (Ø28–45mm) required 45 minutes to changeover, with only 78% first-pass yield.

XIRO Solution:

1. 100+ sets of pre-stored process recipes, auto-loaded via RFID recognition and HMI interaction, reducing changeover to under 90 seconds.

2. Cross-roller guides for 0.3s positioning (±0.01mm repeatability); servo grippers with adjustable clamping force (0.1–5kN).

3. Full data traceability: up to 200,000 press records (force, time, displacement) exportable to Excel or connected to MES.

Result:

Changeover time cut by 83% (down to 90s); first-pass yield up to 99.6%; $220,000 annual cost reduction.

Case 5: Detecting Invisible Cracks via Real-Time Quality Monitoring

Challenge:

One commercial vehicle maker suffered undetected cracks (0.1–0.3mm) in cast iron bushings, losing $180,000 in a single batch recall. Manual inspection missed 18%.

XIRO Solution:

1. Real-time data capture at 2,000Hz for force-displacement analysis; generates SPC charts (CPK ≥1.67).

2. Tolerance window evaluation identifies early signs of cracking via curve anomalies; 3σ deviations trigger instant SPC alarms and shutdown.

3. Full traceability via QR codes: all key parameters (speed, force, hold time), bushing type, and batch records are linked.

Result:

Detection rate jumped to 99.98%, preventing $3.8M in potential losses per year.

Conclusion

With closed-loop control, real-time adaptation, and complete traceability, XIRO Electric servo presses are helping global manufacturers:

• Reduce scrap rates to nearly zero

• Meet IATF 16949, ISO 1101, and ISO 13849-1 standards

• Shorten changeover times by up to 20x

Discover how XIRO Electric servo press technology can help your production line reduce scrap, accelerate changeovers, and improve traceability. Contact us or visit YouTube channel to explore 100+ servo press applications demos across the automotive, aerospace, and precision manufacturing sectors.