Customer Requirement

CSD were approached by a leading global automotive manufacturer who were upgrading their manufacturing facility in order to increase efficiencies and maximise output. As part of this major system enhancement, they required a new EDU (Electric Drive Unit) production line including 32 new build trolleys and 12 build stations each with an overhead DC Tooling and service structure. With CSD’s experience and expertise in bespoke automation projects, we were ideally positioned to deliver this project to the high quality finish expected.

Project Challenge

The biggest challenge to CSD in this Automated Manufacturing Equipment project was the timescale for completion. The customer was looking to update the facility within strict time constraints which meant that CSD had to design, manufacture, test and install this extensive system within 3 months of order receipt, without compromising on our high standards for quality and safety.

The CSD Automated Manufacturing Equipment Solution

The CSD Design Team designed the Automated Manufacturing Equipment to consist of a 42m floor conveyor which transports build trollies through the 12 build stations. An AGV (Automatically Guided Vehicle) system is integrated into the line to transport the completed product to the next process in the plant.

When an AGV is present at the load station at the start of the conveyor, an automatic sensor will signal the conveyor to engage with one of the 32 bespoke build trolleys to pull it forward and start the production process. The trolley is then transported effortlessly to each of the build stations in turn for the relevant production stage until it reaches the end of the conveyor line. At this point a further automatic sensor will detect that the trolley is ready to be removed from the AGV signalling that the EDU is complete.

The build trolleys themselves are designed with kitted parts situated on the left hand side and the engine build on the right. The EDU is located on a trolley turntable so that it can be easily and safely rotated 360 degrees as required by the operator. The dock design also incorporates a safety manual override to allow the operator to release the trolley from the conveyor, if required.

The final part of the system is the overhead DC Tooling and service support structure which consists of a roof mounted structure to reach over each of the build stations. Spanning between the supports are two sets of tooling rails and an Andon pull cable. This allows the operator safe and controlled access to carry out the necessary production step.

This equipment was thoroughly tested at our site in Letchworth, Hertfordshire before it was installed in the new facility as you can see in the images shown. If you would like to see this Automated Manufacturing Equipment in action please visit our company Youtube page.

If you would like to find out more about how one of our Bespoke Automated Assembly Solutions can improve efficiencies in your manufacturing process, please contact us.