1. Method
1.1. Test equipment at I2PS
1.2. Production test in Sirbi
1.2.1. Bypass function test method in Sirbi
1.2.2. Tripping force
1.3. Assembly steps
1.3.1. Bypass assembly
1.3.1.1. Wrong assembled double spring (position the spring on the busbar)
1.3.2. Riveting the bypass to busbar
1.3.2.1. Riveting station wrong setup
1.3.2.1.1. wrong bypass positioning
1.3.2.1.2. lose connection between the bypass and busbar
1.3.2.1.3. riveting force to high
1.3.3. Operator can deform the two ends of the Ausloeswelle during the assembly on the ZM housing
1.3.4. Movement space of the Ausloeswelle spring
1.3.5. Schalteinheit and ZM unit assembly
1.3.5.1. Positioning of the ZM block when assembled to the Schalteinheit
1.3.5.2. Screws tightening torque on the ZM unit to Schalteinheit
1.3.5.3. Schalteinheit-ZM unit assembled into the lower housing (pull out the terminals process need to be checked out)
1.3.5.4. Tightening screws windings (no. of turns) is not checked only the torque is measured
2. Material
2.1. Double spring from the Anchor assembly - responsible for the tripping force
2.1.1. Shape of the spring
2.1.2. Material used for spring
2.1.3. Force of the spring
2.1.4. position of the double spring to Anchor
2.1.5. position of the double spring to strom schiene
2.2. Auslösewelle spring - responsible for correct the lever
2.2.1. Shape of the spring
2.2.2. Material used for spring
2.2.3. Force of the spring
2.2.4. Length of the spring
2.2.5. No. of windings
2.3. Ausloeswelle
2.3.1. Material fault
2.3.1.1. Temperature
2.3.2. Dimensions of Ausloeswelle
2.3.3. Positioning on the Wandler assembly
2.3.4. Friction of the Ausloeswelle assembly (between the connection bolt and Ausloeswelle) (dimensions of the bolt and inner whole of the Ausloeswelle.
2.3.5. Connection bolt between the Ausloeswelle and Wandler housing
2.4. ZM housing
2.4.1. ZM housing deformed
2.4.2. Busbar assembly on the ZM housing
2.4.3. Diameter of the bearing is not correct in the ZM housing (potential molding tool wear-out)
2.5. Magnetic Anchor
2.5.1. Material fault
2.5.2. Dimensions of the Anchor
2.5.3. Positioning of the Anchor in the busbar assembly
2.5.4. deformed Anchor
2.5.5. Anchor shape
2.6. Busbar
2.6.1. Material fault
2.6.2. Dimensions of the busbar
2.6.3. The dimension of the gap (hole) where Anchor is positioned
2.6.3.1. Stamping burr could influence the release
2.7. Axis tripping shaft
2.7.1. Dimensions of the shaft are critical
2.7.2. Material fault (surface treatment, burr)
2.8. Latch
2.8.1. Pollution contamination of the latch assembly
2.8.2. Tripping force (data available in QSYS)