Objective:

• Die cut portions of automotive transmission bands
• Automate material handling

Solution:

• Cam dies for cutting paper and steel portions
• Overhead pick and place mechanism
• Integrated into assembly line conveyor
• Automated part verification
• PLC control with panel view operator interface
• Light curtain for safety

Objective:

• Automate drilling and tapping of Pump Housing

Solution:

• Two-position location fixture for drilling and tapping
• Automatic self feeding drill units
• Automatic Syncro tapper tapping heads
• PLC control

Objective:

• Assemble solenoid into enclosed housing
• Verify correct assembly

Solution:

• Tooling for precise component placement
• Sensors to confirm component placement (Poke Yoke capability)
• Electrical current/load cell system to verify assembly functionality
• Operator assembly fail safe
• Two-hand anti-tie-down

Objective:

• Position 6 sleeves to engine block
• Fit between sleeve and engine block bore

Solution:

• Locating and holding mechanisms to position engine block to sleeves
• Pressure and linear transducers monitor fit of sleeve to engine block bore
• Operator load fail safe with locking clamps for engine block
• Integration of PLC control with data acquisition for quality assurance

Objective:

• Provide flexible orientation for assembly
• Motorize to position stand at component storage points

Solution:

• Hydraulic power unit and rotary actuator for rotational positioning
• Drive motor with gear box for vertical positioning
• Heavy duty drive system for mobility
• Integration of operator pendant and PLC control

Objective:

• Assemble tapered roller bearing onto pinion shaft
• Validation of assembly process

Solution:

• Digital gauging - no calibration required
• Integral air gauging
• Integral verification via end-play measurement
• Integral verification via rolling torque
• Dual model setup, zero changeover

Objective:

• Assemble clutch with correct linear placement of bearings.
• Verify accumulated dimensional tolerance of components.

Solution:

• Linear transducers and load cells used for precision bearing placement
• Gauges with LVDT's used for linear measurements during assembly
• Calibration masters for gauges
• Sensors used for gauge recognition to verify assembly process
• PLC control with data acquisition for quality assurance

Objective:

• Assemble axle housing with correct preload on bearings
• Verify correct assembly

Solution:

• Hydraulic turntable with tooling for tightening axle assembly
• Load cell used for torque monitoring
• Dynamic preload applied to axle bearings
• Over torque monitoring system for quality assurance
• Pneumatic pressure decay test verifies assembly
• Two-hand anti-tie-down

Objective:

• Assemble ignition switch with magnesium housing

Solution:

• Tooling heated to 900F to swage housing
• Tooling for precise component placement
• Sensors to confirm component placement (Poke Yoke capability)
• Pick and place mechanism to transfer heated parts.
• Operator assembly fail safe
• Two-hand anti-tie-down
• Guarding to protect operator from hot tooling

Objective:

• Integrated functionality and life cycle test system.
• Accommodate diverse range of different models/designs

Solution:

• Fully automatic lock-bolt solenoid and key switch functional test
• Three independent test stations, managed with a single control
• Mix and match, all stations/all models
• Servo driven actuator for load and position testing
• National Instruments DAC with LabView software

Objective:

• Measure internal and external components to calculate fit
• Verification of correct shim to be applied

Solution:

• Internal and external gauges with LVDT's for measuring components
• Calibration master for gauges
• Shim verifier
• Sensors used for gauge recognition to verify gauging process
• PLC control with data acquisition for quality assurance