Design and Development of an E-Clip Assembly Station

Project Overview Our company undertook the complete design and development of a precision assembly station tailored for installing E-clips onto automotive components. This station ensured accurate positioning and secure clamping of parts, supporting a production rate of 500 units per day. The project encompassed the full design lifecycle, including conceptual design, 3D modelling, finite element analysis (FEA), geometric dimensioning and tolerancing (GD&T), and the production of detailed manufacturing drawings. Design Process The design process began with a comprehensive analysis of the assembly requirements, focusing on precise alignment and reliable E-clip installation. Using SolidWorks, we developed a 3D model featuring: • Sliding Platform with Electric Actuator: An electric linear actuator provided front and back movement, achieving a positioning accuracy of ±0.05 mm. • Mechanical Clamp: Delivered 100 N of force to securely hold the component in position on the platform. • Vertical Magazine with Dead Weight Guide: Held multiple E-clips and used a dead weight to ensure consistent feeding to the installation tool. • Installation Tool: Designed to apply the necessary force to snap the E-clip onto the component. The station was engineered to handle components up to 5 kg, optimizing cycle time and operator efficiency. Finite Element Analysis (FEA) FEA was critical in validating the structural integrity of the station, conducted using ANSYS: • Static Analysis: Confirmed the installation tool could withstand the assembly force, with a maximum stress of 100 MPa. • Platform Analysis: Ensured the sliding platform exhibited minimal deflection under load. • Fatigue Analysis: Verified the clamp and installation tool could endure over 1 million cycles. These analyses drove design optimizations, such as reinforcing the installation tool and selecting durable materials for wear-prone components. Critical Geometric Dimensioning and Tolerancing (GD&T) GD&T was meticulously applied to ensure precision manufacturing and assembly, adhering to ASME Y14.5 standards: • Positional Tolerances: ±0.02 mm for the sliding platform’s end positions to align the component accurately under the installation tool. • Flatness: 0.03 mm on the platform surface for stable component placement. • Perpendicularity: 0.01 mm for the installation tool to ensure uniform force application. These specifications were integrated into the manufacturing drawings. Manufacturing Drawings Creation Comprehensive manufacturing drawings were produced in SolidWorks, detailing: • Materials: 6061-T6 aluminum for the frame, stainless steel for the clamp and installation tool. • Surface Finishes: Anodizing for aluminum parts and hardening for steel components to enhance durability. • Assembly Guidance: Included exploded views and step-by-step instructions for seamless production. These drawings facilitated efficient fabrication, balancing precision with cost-effectiveness. Key Technical Challenges The project encountered several challenges: • Precision Alignment: Achieving sub-millimeter accuracy for component positioning under the installation tool. • Reliable Feeding: Ensuring consistent E-clip dispensing from the magazine. • Cycle Time: Minimizing time to meet high production targets. Solutions included high-precision linear guides for the sliding platform, calibrating the dead weight for optimal magazine feeding, and streamlining the clamp design for quick operation. Health and Safety Considerations Safety and ergonomics were prioritized: • Ergonomic Design: Controls and loading/unloading areas positioned for easy access. • Safety Features: Interlocks and guards protected operators from moving parts like the sliding platform and installation tool. • Material Handling: Designed for safe manipulation of components. • Compliance: Met OSHA and ISO 45001 standards. These measures enhanced operator safety and comfort. Our Company’s Contribution Our team’s expertise was evident in: • Design Mastery: Utilized CAD and FEA tools to create a precise, robust station. • Innovation: Implemented an electric actuator for efficient and precise movement. • Collaboration: Worked with automation engineers to integrate the station into the assembly line. • Quality Focus: Conducted rigorous testing to ensure all specifications were met. Conclusion This project demonstrates our capability to deliver a specialized E-clip assembly station from concept to completion. By addressing design, FEA, GD&T, manufacturing drawings, and safety considerations, we provided a solution that enhanced assembly efficiency, reduced defects, and prioritized worker well-being—underscoring our proficiency in tackling complex engineering challenges.