Material Handling
The client is a well-established company with over 20 years of experience in developing fully automated systems. They cater to a wide range of automotive OEMs and Tier-1 suppliers, providing tailored automation solutions based on the unique requirements of each production line.
The client approached us to design a turntable for tailgate and glass handling. The turntable system needed to be compact and capable of handling three tailgates with glass panels, moving smoothly across three stations: Loading, Inspection and Unloading.
The system had to index precisely between stations and include a mechanical lock to prevent movement during operations, ensuring safe and accurate tailgate inspection.
Designing a safe and compact turntable for automated inspection of tailgate and glass handling presented several engineering challenges:
After a series of in-depth discussions with the client and a detailed review of their floor plan, operational flow and safety requirements, Sedin Engineering team developed a custom turntable system designed for efficient handling of glass-fitted tailgates.
Leveraging our strong expertise in industrial automation services for material handling, we designed a solution that focused on safety, accuracy, compact size and weight limits, while also making sure it could be easily upgraded in the future.
To meet the strict space constraints of the client's factory, the turntable was designed in a triangular configuration, enabling three working stations within a minimal footprint. This geometry not only reduced rotational travel between stations (120° indexing) but also provided stable weight distribution and easy operator access on all sides.
The frame was designed for strength-to-weight optimization, supporting the fixture assemblies while maintaining structural integrity under repeated dynamic loads.
In the fixture assembly, Station A was designated to load the tailgate with glass, Station B was for inspection and Station C was for unloading the finished part. Each of these three stations had the same fixture setup. This made the process simpler and reduced the need for additional training or setup changes. The fixture design included:
These features ensured repeatable positioning, minimal operator effort and damage-free handling, even in high-throughput environments.
To ensure complete positional accuracy and prevent movement during manual handling or inspection, an external locking assembly was integrated at each station. This lock is sensor-monitored using proximity switches, ensuring the turntable is fully secured before any operation is initiated. This feature meets the client’s safety and foolproofing requirements, reducing the risk of accidental rotation or misalignment during the process.
The turntable was powered by a high-torque motor and precision gearbox carefully selected to handle the complete system load of 1.2 tons. Importantly, the drivetrain was sized with an additional 100 kg capacity in mind. This allowed the client to integrate future components or upgrades without overloading the system.
Before finalizing the turntable design, our team considered the following factors:
This proactive approach ensured long-term reliability with zero risk of performance degradation.
All components and assemblies were validated through a thorough Design Failure Mode and Effects Analysis (DFMEA) process, reducing the chance of in-field failure or rework. The entire system was also reviewed against the client’s ergonomic and safety standards, ensuring:
Additionally, the weight distribution and fixture ergonomics made it easy for operators to handle components without fatigue. This contributed to a safer and more efficient work environment. With the help of Sedin’s cost-effective and state-of-the-art idea, the entire machine was able to work continuously without any hassles, thereby increasing productivity.
The three-station layout allowed loading, inspection, and unloading to happen at the same time. This parallel processing reduced cycle time and significantly boosted output.
The turntable was compact enough to fit into the client’s existing floor space, avoiding the need for facility changes. It was also designed with extra capacity, saving future upgrade costs.
With precise indexing and sensor-based safety locks, the system ran smoothly with minimal downtime and fewer handling issues, reducing costly delays and rework.
The design followed proper ergonomic and safety standards, making it easier and safer for operators to use.
By delivering a well-engineered, high-quality solution, we earned the client’s trust as a valuable design partner for future automation projects.
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