Our Client develops and builds high-quality, cost-effective state-of-the-art automated solutions for the automotive, medical, and other industries across North America.


The scope is to design an automatic workstation either to insert an aluminum nameplate and bend its tabs or to insert plastic tread into the rear doorsill plate. 

Why APA? 

APA has around 8 years of experience in the design of automation equipment, welding fixtures, assembly line automation, work stations/work cells, and EOAT (End Of Arm Tools).

Design Challenges involved: 

  • The challenge was to design a single workstation for the operations explained in the scope. We used a vision camera to identify the input component and design a suitable mechanism for each of the operations.
  • Bending 13 small tabs of the aluminum nameplate in a small area was a challenge. We designed 13 numbers of small punches with 2 linear actuators for this objective.

Design Process:

  • Understanding the station’s requirement and Sequence of operations performed and determine the design elements
  • Designing the nests to hold the components and determining material depending upon the component to be held.
  • Performing Sizing calculations to select Linear guides, Linear Actuator, and Rod lock cylinder.
  • Designing a vertical movement mechanism by using linear bushing and shafts to push the tread/nameplate into the sill plate. 
  • Incorporating safety features such as light curtains, Shot Pin cylinder, Rod lock cylinder, and emergency stop.
  • Designing different hole positions and hole sizes for assembly process Poka-Yoke.
  • Using a vision camera to identify the type of input component. 
  • Considering the ergonomic aspects such as table height, operator reach, etc. 
  • Incorporating proximity sensors to know the stop positions of various mechanisms in this assembly. 
  • Preparing parts, assembly drawings, and Bill of Materials.

Value Delivered:

  • We have performed sizing calculations of long-lead items such as Linear actuator, Linear guides, shot pin cylinder, etc., and get the confirmation from the respective manufacturers during the initial stage of design completion. This helped to speed up the construction schedule. 
  • APA Engineering is an “On-Demand Extended Design house” for our client. Design cost was just 40 % when compared to onshore. 

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