andron design portfolio final
DESCRIPTION
Various Assistors I designed for Jaguar Land Rover Rolls Royce for use in their assembly lines during manufactureTRANSCRIPT
Thames Industrial Estate • Fieldhouse Lane • Marlow • SL7 1TB • United Kingdom
www.andronhandling.com [email protected] 0845 075 8211
Design Portfolio
APRIL 2014
Jaguar Land Rover JLR Spare wheel Assistor
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Requirements: to pick all variants of spare wheel for L494 (Range Rover sport) X760 (new jaguar XE) and X761 (new Jaguar SUV), 8spare wheel variants in total ranging from a 20” alloy full size spare, to a pressed mild steel space saver spare. Wheels to be picked up horizontally from a delivery stillage and transferred into the rear of the relevant vehicle.
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CLAMP JAW STRESS CALCULATIONS AND FEA
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Clamped cross sections through worst case spare wheels to be handled
Outer nylon cone extends to allow for the difference in internal wheel bore diameters.
Central pin extends to open the jaws, and retracts to close the jaws, the clamp jaws are mechanically locked in each position so it will not drop the part in the event of complete and sudden air failure.
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Rendered Cross section
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Rolls Royce Blade C-Scan AssistorRequirements: To pick flat pack blades from a “toaster rack” style stillage, rotate it 90° and place it submerged
in a water tank for the Rolls-Royce C-scan procedure to take place. The C-Scan is an ultrasonic scan of the
blade to check for impurities / defects / contaminants in the metal blades. Once the scanning operation was
complete, the assistor would then pick the submerged blade up out the C-scan tank, rotate by 90° and back
into the stillage.
The assistor was to handle all blades from all the Rolls-Royce engines from the Trent 500 to the Trent XWB , 8
variants in total with a maximum safe working load of 65kgs.
A few design requirements had to be considered before the design could begin:
• How would the performance of the pneumatic vacuum generator be affected when water is introduced into
the system?
• How would the vacuum cup performance be affected when picking up in a water filled environment.
• This was a very corrosive environment so the end effecter was to be made of stainless steel, all pneumatic
fittings were to be stainless steel, pneumatic cylinders were to be corrosions resistant, clean room and food
industry standard.
• To avoid any contaminants entering the C-scan tank all bearings and bushes had to be sealed and no oilite
bushes to be used.
• No silicone based materials were to be in contact with the blade, a nitrile-pvc vacuum cup from PIAB was
chosen.
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SCOPE OF ANDRON SUPPLY
STAINLESS STEEL PARKING STAND
STAINLESS STEEL VACUMM END EFFECTOR
350LB BALANCER, KBK2 TROLLEYS AND PNEUMATIC CABINET ASSEMBLY
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CORROSION RESISTANT ROTATION CYLINDER, CLEVISES, AND PIPE FITTINGS
OPERATOR HANDLES WATER RESERVOIR
STAINLESS STEEL PARKING STAND
PIAB F 150 NITRILE PVC VACUUM CUPS
C-SCAN END EFFECTOR
90° ROTATION
STAINLESS STEEL LIFT EYE
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END EFFECTOR PARKED
JUNCTION BOX
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END EFFECTOR CONTROLS
VACUUM RELEASE FINGER LEVER
VACUUM ON FINGER LEVER
ROTATE 2-POSITION SWITCH
VAC OK GREEN PNEUMATIC INDICATOR
PARKING BRAKE 2-POSITION SWITCH
VAC ON AND RELEASE ENABLE FINGER LEVER
ZA PROPORTIONAL LIFT CONTROLS
DETENT PLUNGER
HANDLE ROTATION STOP BOLT
FULL STAINLESS STEEL CONSTRUCTION
RUBBER HANDLE GRIPS
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HANDLE MOUNTED ON AN ADJUSTABLE CLAMP PLATE
DETENT PLUNGER BUSH
REPLACABLE STAINLESS STEEL WEAR PLATE
HANDLE ROTATION STOP BOLT RUNS IN SLOT AND ELIMINATES FINGER TRAP
HANDLE AND RESERVOIR MOUTING
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*ROTATION CYLINDER HIDDEN FROM VIEW IN THIS SCREEN SHOT
VIEW OF HANDLE ROTATION STOP BOLT RUNNING IN SLOT
WATER RESERVIOR HELD IN PLACE WITH STAINLESS STEEL TUBE CLAMP, FOR ADJUSTMENT AND EASE OF REMOVAL
WATER RESERVIOR
HANDLE AND RESERVOIR MOUTING
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WATER CATCHMENT RESERVOIR
3” x 1.5mm STAINLESS STEEL TUBE
PIAB INLINE VACUUM GENERATOR
WIRE WOOL SILENCER
BOTTOM END CAP
ATTACHMENT SCREWS
TOP END CAP
WIRE WOOL SILENCER
2 x ELBOW
Ø8mm BULKHEAD ONE TOUCH FITTING
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ADJUSTABLE ROTATION USING CYLINDER ROD COLLAR
STAINLESS STEEL CYLINDER ROD CLEVIS
STAINLESS STEEL PIPE FITTINGS
ALL FINGER TRAP POINTS HAVE BEEN REMOVED AT ROTATION JOINT
90° VACUUM CUP ROTATION AND MOUNTING
STAINLESS STEEL THREADED VACCUM CUP MOUNTING SHAFT
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Jaguar F-Type Coupe Body side assistor.
Requirements: To pick the F-type coupe aluminium body side panel from a delivery stillage, rotate it through 90° and
place on to the f-type coupe Body in white frame ready for the riveting/welding process to take place further down the
line.
One assistor on each side of the line for left and right hand side body panels.
Picking up on the body panels A-surface, care had to be taken to prevent any A-surface from being contacted by
anything other than soft nylon, polyurethane and rubber.
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Requested cross shop steel work to be added
Existing Rivet gun cross shop rail
Existing Rivet gun down shop rail
New assistor down shop rail 5m length
Air supply point:1/2” BSP Femalewith Ball ValveCustomer to supply
Air supply point:1/2” BSP Femalewith Ball ValveCustomer to supply
Alternative option pending reach calculations:Extend rivet gun down shop rail and run body side assistor carriage in the same down shop rail.
Layout
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Storyboard
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Storyboard
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Storyboard
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Storyboard
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Storyboard
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AutoCAD Layout Overlay
Pick Controls
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Vac on levers
Vac ok pneumatic indicator
Brakes on/off push button lever
Junction box with pneumatic balance trim adjuster knob
Place Controls
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Vac ok pneumatic indicator
Release push button lever
Brakes on/off push button lever
Release push button lever
Rotate Controls
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Rotate to place position push button lever
Rotate to pick position push button lever
Vac ok pneumatic indicator
Brakes on/off push button lever
Enable push button lever
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Elephants Trunk nylon Vac cup
locator
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Adjustable rotation stop
Adjustable rotation stop - adjustable from 0° to 190°
Control Scheme
• Press ‘brake’ lever on pick controls to release brakes
• Manoeuvre assistor over to the part in the stillage and visually locate assistor to the part using the nylon locators as guides.
• When satisfied that it is located, press both ‘Vac on’ finger levers to switch on the vacuum circuit
• When a successful vacuum has been reached the ‘Vac ok’ indicator will illuminate and automatically switch the assistor into the higher balanced load. Use ‘balance’ knob to adjust the balance trim as necessary.
* NB - If the part is not correctly located in the assistor it will not generate a successful vacuum, the ‘Vac ok’ indicator will not illuminate and the assistor will not switch to Load.
• Carefully remove the Assistor and component from the stillage and manoeuvre into a clear space ready for rotation.
• Press ‘brake’ brake lever to apply brakes and move into position in front of rotate handles.
• If necessary press brake lever from rotate handles to release brakes and readjust assistor position as necessary to clear any potential obstacles, then apply brakes again when you are satisfied all obstacles are clear.
• From rotate handles press the ‘enable’ lever along with ‘rot right’ lever to rotate part from pick to place position.
* NB – Brakes should be applied during the full rotation of the part to avoid assistor drifting into build fixture or stillage.
• Move into position in front of place handles, press the brake lever to release the brakes again and locate the part in the build fixture.
• Once located, press both release levers to switch off the vacuum circuit and release the part, this will automatically switch the assistor back to the lower balanced load.
• Move assistor to safe or parked position for repeat operation.
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L538 (Evoque) and L550 (Freelander 3) Axle Lifter
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Requirements: Design a frame manually operated lifting frame to pick the fully assembled axle assembly from build
fixture and transfer over to marriage tug using existing Demag electric hoist and existing overhead trackwork. There was
no pneumatics in the axle build area so any clamps had to be manually operated.
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L550 proposed pick point
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Stress Calculations and FEA
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Final Design after calculations
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