GEN2 & GEN3 Plant Fitment Procedures - Grommet Seal v1.0

8/8/2019 GEN2 & GEN3 Plant Fitment Procedures - Grommet Seal v1.0

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PLANT ASSEMBLY PROCESS FORSCHRADER ELECTRONICS GEN2 & GEN3 TPMS TRANSMITTERS

PLANT ASSEMBLY PROCEDURES FOR

GEN2, GEN3 & GENJ TPMS TRANSMITTERS

FITTED WITH LARGE GROMMET, HYBRID SMALL GROMMET OR SMALL GROMMET SEALS

HYBRID SMALL GROMMETLARGE GROMMET

SMALL GROMMET SMALL GROMMET


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INTRODUCTIONThis document details the Schrader Electronics process recommendations for wheel plant assembly forGEN2 and GEN3 TPMS transmitters fitted with either Large Grommet, Small Grommet or Hybrid SmallGrommet (HSG) seals, and GENJ TPMS transmitter fitted with Small Grommet seal.

CONTENTS

What NOT to do during assembly

Storage Conditions

Transmitter manual rim mounting procedure

Common Nut Torque Profile

Plant assembly recommendations for linear conveyor and rotary table type wheel assembly

Transmitter Verification

Line Trials


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Typical GEN2 Transmitter Assembly

WHAT NOT TO DO DURING ASSEMBLYNever fit a damaged transmitter or seal to a wheel rim.

Do not fit the tyre to the rim unless confident that the valve and seal have been fitted correctly.

Never interchange seal types between transmitters.

Never re-use an old seal. Always ensure that a new Schrader seal is fitted to the transmitter.

Never fit a transmitter to unapproved wheel rims.

Never use an automated tyre matching process without prior consultation with Schrader Electronics.

STORAGE CONDITIONS

Transmitters should be stored in a dry ambient environment, avoiding damp conditions and extreme

temperature exposure. Typical storage temperatures are 0 to 40C, short term exposure outside these limits

is permitted.

The shelf life of the transmitter is 10 years from date of shipping. However the shelf life of the seal is 24

months from date of shipping. Seals that are aged more than 24 months from shipping date should not be

used. If a seal is found to be more than 24 months old, then it should be removed from the transmitter and

replaced in accordance with the workshop procedures detailed in this document. The shipping date will be

given on the label of the Schrader shipping box, if this is unavailable use the date clock found on the top of

the transmitter enclosure.

X

ENCLOSURE

VALVE

SEAL

CAP

X

X

X

X

X

NUT


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TRANSMITTER MANUAL RIM MOUNTING PROCEDURE

Place the valve in front of the hole.

Ensure the valve is inserted centrally tothe valve hole.

1 The seal must be positioned centrally tothe valve hole. Ensure the seal lip is nottrapped during insertion. Push the rear ofthe enclosure.

2

Hand tighten the nut until it touches therim.

3 For transmitters fitted with HybridSmall Grommet ONLY, use a calibratedtorque wrench set at 80.5Nm.

4 !

For transmitters fitted with Large

Grommet or Small Grommet sealsONLY, use a calibrated torque wrenchset at 50.5Nm.

5

5Nm

Hold the transmitter in the valve hole

while torquing. Slowly torque until thewrench reaches relevant setting (8Nm or5Nm).

6!


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Do not push the top of the enclosurewhilst torquing the nut.

7 Do not lift the enclosure whilst torquingthe nut.

8

A correctly positioned transmitter lookslike this when fitted.

9


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COMMON NUT TORQUE PROFILE

Schrader Electronics have developed a common nut torque strategy for automated torque wrenches that isused on all Schrader TMPS transmitters. If the Customer is using a different torque profile that has beenpreviously approved by Schrader Electronics, then this too is acceptable.

The automated nut torque profile is shown below and consists of the following:

1. 30rpm x 2 revolutions

2. 300rpm (10%) to 3Nm (0.5Nm)

3. 50ms stop

4. 30rpm (10%) to 7Nm (0.5Nm) reducing to 18rpm (10%) to 8Nm (0.5Nm)

If the torque wrench is not capable of producing step 4 of this profile, then this step can be replaced by thefollowing simplified step:

4. 20rpm (10%) to 8Nm (0.5Nm)

Plant audit checks are best done as part of the wheel mounting process. These should be performed less

than 15 minutes after fitment of transmitter. Residual torque should be above 2Nm.

Time

Speed

Torque

3Nm

7Nm

8Nm

300rpm

30rpm18rpm


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WHEEL ASSEMBLY PLANT RECOMMENDATIONS

After the transmitter has been mounted to the wheel rim, the rim is introduced to the automated tyre fitting

machine. To avoid damage to the transmitter, this process MUSTdetect the location of the transmitter prior

to tyre mounting, and position the transmitter in an orientation so that at the tyre beading station, the

transmitter is orientated at the 1:30 2 oclock position.

There are two typical assembly methods in use at wheel assembly plants, and Schrader Electronics has the

following recommendations for each method:

LINEAR CONVEYOR

On tyre fitment processes where the roller moves in a clockwise direction, the transmitter needs to be

positioned in the 10 10.30 oclock location

1

2

3

STATION 3

Typical 12 oclock position to start and finish the

tyre beading process. Arrow shows direction of

beading tool rotation.

STATION 1

Wheel rim introduced to conveyor and the

transmitter located in correct orientation by sensor

at 1:30 2 oclock position

STATION 2

Tyre dropped onto wheel rim. The lowest part of the

tyre should be at the 12 oclock position.

Sensor detection and tyre fitment processes must NOTintroduce any load and/or damage to the transmitter.


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ROTARY TABLES

STATION 1: Wheel rim placed on table with transmitter located in correct orientation.

STATION 2: Tyre dropped onto wheel rim, lowest part of tyre at 12 oclock position.

STATION 3: Roller begins to seat the tyre beads at 12 oclock position, and moves anti-clockwise until

the 3 oclock position. Both beads are seated onto the wheel rim.

STATION 4: Final station wheel assembly removed by robot for inflation and balancing.

On tyre fitment processes where the roller moves in a clockwise direction, the transmitter needs to be

positioned in the 10 10.30 oclock location.

WHEEL

DIRECTION OFTRAVEL OF TABLE

1

2

3

4

ROLLERSTARTPOSITION

ROLLERENDPOSITION

TABLE

GEN2TRANSMITTER

TYRE


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TRANSMITTER VERIFICATION

It is typical to use transmitter verification at the end of the line, i.e. after tyre mounting, inflation and

balancing are completed, to ensure that the transmitter has not been damaged during these processes.

Verification will involve a separate station: Plant transponder tool: when a 125 KHz activation frequency is applied, transmitter data can be

read back to the LF station via the 125 KHz field. If the 125 KHz activation frequency remainspresent for longer than 3.5s, then an RF transmission will be triggered and this can be read-backto an RF station.

Transmitter emits RF response (transmitter ID & pressure data)

If no transmitter response or if tyre pressure out of specification then alarm is activated

If a wheel assembly containing a transmitter needs to be reworked, this must be done in accordance with

the workshop procedures detailed in Schrader Electronics document no. 90580022 for transmitters fitted

with Small Grommet, Hybrid Small Grommet or Large Grommet seals or document no. 90580022 for

transmitters fitted with Conical seals. These documents should also be used during any quality inspection

that involves tyre removal.

Direction of travel

Antenna assembly connected to either remote PC or

main host plant PC. The antenna is capable of checkingtransmitters in any position on the rim.


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LINE TRIALS

The line trial is the method for validating fitment of Schrader Electronics clamp-in TMPS transmitters. Its

purpose is to build a quantity of rims on production equipment & at production rates. A line trial would be

used in a new assembly location, or upon the introduction of new equipment or a new rim design, and

should be conducted on a minimum of 20 rims for each rim type for a good data spread.

A line trial typically consists of:

Valve Hole Check of the wheel rims, see below.

Fitment of Scharder Electronics TPMS Transmitter carried out in accordance with this document

Transmitter Fitment Checks, see next page

Automated fitment of tyre, tyre matching (optional) & inflation

Post Line Trial Checks

Note that wheels do not require to go through a wheel balance station as part of the line trial.

VALVE HOLE CHECKS

On a sample quantity of rims perform the following visual checks:

Check hole diameter is 11.5 +/-0.2mm

Check chamfer on inner face of wheel is 0.5 +/-0.3mm

Check chamfer on inner face of wheel is centred on valve hole axis

Check diameter of flat on outer face of wheel is minimum 14mm diameter

Check chamfer on outer face is maximum of 0.25mm

Rim thickness is: between 2.5 & 4mm for transmitters fitted with Large & Small Grommet seals

between 1.5 & 4mm for transmitters fitted with HSG seals

Non-centred chamfer (inner face of valve hole) Large chamfer (outer face of valve hole)

LargeChamfer

SmallChamfer

LargeChamfer


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MOUNTED TRANSMITTER CHECKS

Ideally the top of transmitter is to bebelow Bead Hump. If this is notpossible then it must be less than 2mm

above the bead hump.

Enclosure front face must not touch rim face.

Bead Hump

There must be a gap under centre-line oftransmitter of between 0.5mm and 4.3mm.

Transmitter will rotate in the same direction asapplied nut torque. However if it rotates inopposite direction then there could be apotential issue

It is OK for the transmitter to be rotatedduring the mounting process and lower edgetouches the rim. However there must be agap under the sensor as shown in thispicture.

Nut should be central in counterbore. In thisexample nut is not central.


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LINE TRIAL CHECKS

Check valve hole condition

Transmitter function check with LF transponder tool

Initial tyre pressure measurement (preferably using a digital pressure gauge)

Leave for 72hrs before performing the following checks:

Measure residual nut torque in tightening direction

Ensure torque to rotate nut & transmitter assembly is not measured (place a paint mark between

the valve & nut before tightening)

Measure tyre pressure (preferably using a digital pressure gauge)

Remove transmitters using Schrader recommended workshop guidelines, document no. 90580022.

Perform visual inspection on transmitter enclosure, seal and wheel rim for any damage, see below.

Record all results.

Seal split damage ontop & bottomsurfaces

Abrasion marks onenclosure

Potting cracks

Documents

GEN2 & GEN3 Plant Fitment Procedures - Grommet Seal v1.0