Automated 1st Stage of Assembly Process – Automotive
This project was part of a series of fully automated assembly machines designed and built for an automotive client. I acted as the lead mechanical design engineer, responsible for the complete mechanical design and system concept, client communication, and coordination with the automation department.
The machine is based on a six-station rotary indexing table integrated within a modular aluminum-frame enclosure. It includes:
– Three bowl feeders supplying plastic components,
– Two ultrasonic welding stations equipped with sonotrodes,
– A quality control and inspection station,
– A sorting mechanism for separating good and rejected parts,
– A Beckhoff PLC-based control system integrated with pneumatic and electric actuators.
Component transfer between stations is executed mainly via pneumatic cylinders, with the rotary table providing synchronized indexing movement.
My responsibilities covered:
– Developing the complete mechanical concept and detailed 3D design in SolidWorks,
– Selecting components and preparing manufacturing documentation,
– Managing technical discussions with suppliers and automation engineers,
– Supervising assembly and integration on-site,
– Supporting PLC and HMI integration, functional testing, and final commissioning.
This project demonstrates my capability to lead end-to-end design and delivery of complex automated systems, combining mechanical precision, process reliability, and production efficiency.