Fabrication Case Study (Drive Shaft Press Assembly) - Tech-Con Automation
Robotic Palletizing solutions case study by Tech-Con Automation
Palletizing Solutions
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Fabrication Case Study (Drive Shaft Press Assembly)

An automotive manufacturer approached Tech-Con Automation about replacing its ineffi cient and unreliable equipment. The customer’s main objective was increasing efficiency by combining two driveshaft sub-assembly operations into one workstation. This would decrease
logistics costs by eliminating the need to double handle parts. The customer also wanted to improve assembly error-proofing with the introduction of part checks, cameras and poka-yoke mechanisms.

Customer Needs

    • The customer required several complex assembly, test and part-handling operations to be housed within a small work station.
    • Changeover solution: The process required multiple different part combinations to be processed in the same workstation. Tooling was designed and implemented that provided an accurate and quick changeover solution.
    • Part fixture: Pressing the spindle, staking the nut and torquing the damper bolts created large loads on the parts being processed. A part fixture with a robust design was an absolute necessity.
    • Cycle time issues: The parts had to be manually loaded into the fixture, nuts loaded and torqued, and the spindle nut staked into a random radially located keyway. This had to take place within a short cycle time while maintaining tight tolerances.


Our Solution

    • Tech-Con team developed a reliable and repeatable solution that addressed space, efficiency and numerous technical requirements. In seconds, the machine could be configured to assemble different drive shaft models by exchanging the “quick change” fixture tooling, damper nut clamps and the torque gun sockets.
    • A Cognex Vision inspection system was integrated into the staking operation to determine the radial position of the keyway on the spindle shaft. The staker was then rotated via a servo motor to match the angle of the keyway and was actuated to stake the nut into the keyway on the spindle shaft. Parts were held securely in the correct positions by a pneumatic clamp mechanism during the staking operation, and nut clamp assemblies were locked in position by pneumatic actuators during torquing.



    • The end result was a system that increased efficiency, accuracy of part handling and simplified logistic requirements. In addition, equipment components were modular and self-contained, providing flexibility in the event of changes to space requirements in the future.