**This page presents a carefully curated collection of mechanical design and manufacturing projects that I personally designed, with full intellectual property rights retained by me, and also oversaw the manufacturing process. All intellectual property rights related to the works showcased here are exclusively owned by me. Unauthorized use, reproduction, or distribution of the content without explicit permission is strictly prohibited and may result in legal action.
Category: Automotive Manufacturing / Robotic Automation Fixture Design
Material: Aluminum 5000 Series Alloy (Monoblock Structure)
Manufacturing Method: CNC Milling and Machining
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Manufactured Part:
This project is an original assembly fixture I designed following R&D for Bosch factories producing diesel injectors in the automotive sector. All intellectual property rights of the design belong to me. This assembly fixture ensures the safe and accurate arrangement of injector needles by robotic arms in the factory and serves as a basket for transporting the needles.
The existing assembly fixtures (assembly jigs), manufactured by bending and welding stainless steel wire rods, suffered from issues such as weld point failures and deformation due to drops, impacts, or prolonged use. As a result of the deformation, the frame shifted several millimeters beyond tolerance, preventing the robotic arms from performing the arrangement. The robotic arms would collide with the baskets, posing occupational safety risks and causing production line stoppages that led to significant efficiency losses.
Moreover, the detection of faults, welding repairs, storage, logistics, and engineering follow-up related to the malfunctioning assembly fixtures negatively impacted operational and managerial efficiency.
To address these issues, I designed a new assembly fixture made from high-strength Aluminum 5000 series alloy with a monoblock structure suitable for robotic production environments. Compared to the existing stainless steel model, the new design provides a 29.5% reduction in weight (from 2980g to 2100g), significantly reducing the total load on operators.
The developed aluminum body demonstrated superior mechanical durability by withstanding standardized impact tests without deformation or breakage even when dropped from 3 meters. It continued to operate under robotic arms, proving its robustness beyond the required standards.
Consequently, the failure rate of assembly fixtures was reduced, resulting in the following improvements: