INDEX-6 | Machine design from load path to control logic

Original six-station assembly and inspection machine study by Arya Singh. The concept coordinates an XYZ transfer head, indexing dial and nests, guided press, conveyors, camera/height inspection and reject handling. The case study follows a specific problem through the design. The proposed backing lift supplied about 402 N theoretical air force against an approximately 892 N press scenario. I introduced an integral plunger shoulder, captive steel support fork, spring-engaged retaining pin and a reaction plate connected to the press feet. Air positions the mechanism; the modeled steel path reacts the press load. I carried the revision through mounting holes and fastener grip stacks, sensor/solenoid interfaces, wire and chamber-line routes, interlocks, wear points and timing. The selected support sequence is about 4.37 s within the modeled station dwell. The 3.6 kN load screen uses explicit steel/beam/contact assumptions; it is not a measured capacity rating. The first interference run found clashes with the dial-bearing support and mounting hardware. The preserved result led to relief pockets, narrower fork/guide spacing and a shifted actuator. Rechecking the selected structural pairs and support poses found no remaining overlap in that scope. Separate file checks compare component identity, placement and volume after export, with independent equations for critical parts. Images are actual CAD renders and original diagrams. This is a self-initiated engineering-review concept, not a manufactured client machine or certified safety system. Exact supplier interfaces, complete continuous-motion/routing qualification, final manufacturing tolerances and physical trials remain release work. Workflow: AI-assisted build123d/OpenCascade, STEP, Blender and documented calculations. Required native formats are agreed per job.