Case Studies

Here are some of the examples of how Raptech has designed & engineered customised products for different client needs. 
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Material Handling
Trolleys & Pallets

Vehicle Roof Storage Pallet

Case Study 01

Overview:

Roof is the most delicate part in the vehicle chassis system. A thin sheet of metal forms the roof of the vehicle, therefore handling such parts with a conventional storage system is difficult. Raptech has designed and developed its own product for handling such type of material, called as Clinker Tower. A ‘Clinker Tower’ consists of ‘Fingers’ where the roof is going to rest. Raptech created a special mechanism that is designed for such critical applications, where, when a roof is loaded on its first finger, the next finger above it will open automatically for loading the next part.

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01

Requirements

Variants : 02 Nos

Part Density/Pallets :

08 Nos

Maintaining 10 mm Gap between two parts​

The requirement was to minimise product

damage and ensure safe loading and unloading. The product keeps the vibration in control and ensures operator safety.

02

Challenge

The roof part is heavy and wide. Owing to its sizeable length, it is difficult to load/unload the part into the pallet, resulting in damage or mishaps.

03

Solution

A special type of product was designed. Clinker Tower operates on a mechanism in which, when force is applied on the first finger, it automatically pops the immediate next finger open by up to 50% for loading the next part. The process is repeated till 22nd part gets loaded on the pallet. Three towers from right and three from left are distributed in such a manner that the actual form of the roof is maintained.

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Paint Shop
Jigs & Skids

Passenger Deco upper Applique Painting Jig

Case Study 01

Overview:

Passenger deco upper applique is an A-class part in the vehicle. The part is delicate and needs special attention to control the warpage condition during the paint drying process. We designed this critical jig to achieve the final shape of the product even after coming through the oven.

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01

Requirements

  • Accuracy: 0.2 to 0.5 mm

  • Minimum 5 parts to fit in one jig

  • Parts should not wrap during painting process

  • Easy loading/unloading with agronomic conditions

02

Challenge

The part was too delicate to handle, and it was essential to control warpage conditions after drying in an oven. The jigs had to be sealed enough to avoid stacking of soil and paint pigments. Size and the weight of the jig, too, were a challenge.

03

Results

The delicacy of the part is controlled by holding it on 3 rigid points with the help of tension springs. To achieve the accuracy, all the child parts were laser cut. All the holes, cut-outs, were plugged and welded to seal the jig. To reduce the weight, square tubes were used

Case Study 02

Door painting jig

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Overview:

In the manufacturing and automobile industry, paint jigs are very important. It helps speed up the robot or manual painting process, while achieving the best paint effect and paint surface. This tool is cost effective and can be customised for a number of variants

01

Requirements

  • Accuracy: 0.1 to 0.2 mm

  • No of Variants: 04 vehicles (common for 24 doors)

  • Part to hold form and remain steady, even when exposed to heat

  • Limit part damage in handling. Ease of loading and unloading during assembly

  • Operator Safety (Sharp Edges

  • Quick turn-around

02

Challenge

The jig needed to hold four doors of a vehicle during the painting application over an automated moving conveyor line at robotic painting stations. The oven temperatures can affect the form of the part over the period of time which was another challenge.

03

Results

We designed a special painting jig that can be effectively used for 24 door variants.

Our plastic jig for painting can be used to hold front and rear doors (LH-RH FRON & REAR) for 6 car variants

Also jig accuracy and reputability is within +0.1 or -0.1 which allows the use of jig under robot application.

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Fixturing & Ailled 
Solutions

Case Study 01

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8AT - PTU - Transmission Assy Table

Overview:

Assembly of Power Transmission Unit and Automatic Transmission is done on a single table. The whole system consists of a Jib Crane, Holding Fixture, Assembly Table, PLC Control Panel with Elipse SCADA and a Electric Screw Driver with its Drive. System is

semi-automatic and common for two variants of Automatic Transmissions and three variants of Power Transmissions.

01

Application

Assembly of 8AT and PTU with NUT Runner 

02

Challenges

Accuracy: 0.1 to 0.2mm

No of 8AT Variants: 02 Nos

No of PTU Variants: 03 Nos

Tightening Torque: 60 Nm

Accessibility of nut Runner at every bolt and the Spline gear alignment, repeatability & Traceability was a major challenge.

03

Components

1.  Jib Crane

2. Reaction Ram

3. Modular Fixture for 8AT

4. Modular Fixture for PTU

5. Assy Table

6. PLC Control Panel

7. Electric Screw Driver

8. Barcode Printer

9. Lifting Tackles

10. Changeover Stands

11. Tackle Stand 

04

Solution

(Mechanical)

There were total 7 bolts to be tightened at different location to complete the assembly which has be doe with Electric Screw Driver. The torque is massive and to nullify it the Screw driver was Mounted on the Reaction Arm. All the variants of both parts accommodated in the modular fixture with collapsible miller technology which were Hard-crome Plated to avoid corrosion.

05

Solution

(Electrical)

 

Every Tightened bolt with a set torque which has to be saved in a PC hard disk against a part no of the operator before the start of assembly. Once the part is fully tightened and assembled with each other, a new assembly part no barcode is automatically been generated by the system which is pasted the aseembly.

06

Results

A perfectly repeatable system is successfully installed at the customer end. The traceability of every part can be obtained with few clicks.

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Vehicle Assembly 
Tooling

Notchback Tailgate Spring Extension Tool

Case Study 01

Overview:

Spring to mount car body with no tool is very difficult because spring requires tremendous force to expansion. This particular fixture was used to Expand LH-RH tension springs and load at a desired location on tailgate & car body. Another important function of the fixture was the ease of use and durability. 

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01

Requirements

  • Common handling tool & fixture for LH-RH side mounting

  • Ease of handling and agronomic condition on car body

  • Tool should not damage car body & spring

02

Challenge

While designing this fixture and hand-tool, the fundamental challenge was to create a tool that facilitates ease of operation because time was of essence here. An operator had to expand the tool and manually fit it on the car body within 1 minutes 20 seconds.

03

Solution

Raptech developed a custom make fixture & holding tool that could expand spring and offer ease of operation while fitting on the car body. It was durable, efficient and convenient. It could expand two springs in one stroke, saving both time and effort as compared to the conventional method. Pneumatic operating system makes the operations easier and user friendly. To avoid any damage to the car body while working, we provided a special plastic coating over the handling tool.

Pressure rollers

Case Study 02

Overview:

Tooling is an important process in the production and assembly of automobiles today. A typical vehicle has some metallic parts and some parts made of ABS plastic. During assembly we need to press the plastic parts against the metallic part in the given slots. Additionally, an adhesive tape might be required to stick the part firmly on the metal surface. This tool applies customised and equal pressure on the part irrespective of its shape. 

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01

Requirements

  • Should exert identical pressure on plastic parts surface while pressing with force adjustment

  • Ease of handling

  • Agronomic condition on car body & light weight

  • Tool should not damage the car body’s finished painted surface

02

Challenge

The biggest challenge in this tool was to avoid any kind of damage to car body’s finished surface. As we are working in the final stages of car production, any damage would result in rejection of complete car body and multiple reworks.

03

Solution

Raptech developed a custom holding tool that could help in this pressing operation. We provided a rubber roller to avoid any damage to the car body surface. Roller operates on a mechanism in which when force is applied on the plastic parts surface, it automatically releases the lock and starts rolling with set pressure. The tool is designed in such a way that we can set variable force value as per requirement and use it for multiple parts.

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SPM & Automation 
Solutions

MFE ASSY Fixture

Case Study 01

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Overview:

This Fixture is built for assembling Radiator housing and the Front end bumper of the car. The fixture was semi-automatic in nature with purely pneumatic circuit.

Miss alignment (due to manual assy) in the front end bumper and the radiator housing was visible by the customer even after the final assembly of the vehicle. There were two variants with different heights need to be accommodated in the same fixture.

01

Application

Front End Module and Radiator Housing Assy Fixture

02

Challenges

Variants : 02 Nos

Accuracy : 0.2 to 0.3mm

  • No Electrical Components to be used

  • Low cost automation

  • Two variants to be accommodated in the same fixture

03

Solution

Rigid Locating and Resting Fixture for both Radiator housing and Impact Bar.

Fully pneumatically operated system with heavy duty Clamping Cylinders. Two different Pneumatic Operator Panels for both variants.

04

Results

A perfectly robust fixture for assembling both variants in the system.

Air vent metal axis pin
assembly machine

Case Study 02

Overview:

Manual assembly process impacts the speed & quality of the production. There is a higher risk of error because of human intervention.

To eliminate this problem, we designed and manufactured a fully automated SPM which can assemble small size pins at perfect positions with high volume; it has auto feeding mechanism, pick and press unit and sensors at multiple locations for fast production. 

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01

Requirements

  • Common handling tool & Fixture for LH-RH side mounting

  • Ease of handling and agronomic condition on the car body

  • Accuracy between 0.05 to 0.1 mm

02

Challenge

The precision required, and maintaining the operator safety from sharp edges of the pins, was the biggest challenge. Maintaining uniform distance between pins and quick turn-around was another challenge.

03

Solution

A special type of machine was designed that included a pin feeder for continuous supply and holding + pressing pin set that was used for pin engagement. We additionally provided side guards to avoid human intervention. PCL operated servo motorised system gives higher accuracy with repeatability and mass production.

EPP Trays & Plastic
Moulded Parts

Non Metallic Packaging Boxes 

Case Study 1

Overview:

Mostly to protect A-Class parts of an automotive, a Non Metallic Packaging Boxes are used. Expandable Polypropylene (EPP) is niche material which is attracting a lot industries now a days. It has exorbitant shock absorbing properties, hence it is used in material handling explement. Other stan shock, it is Water, Oil and Corrosion Resistant.

In the reference images shown is a Packaging Box made up of EPP for transporting ORVM

Assemblies common for 8 variants including LHD and RHD vehicles.

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01

Application

ORVM packaging box for transportation

02

Challenges

Variants : 08 Nos

Part Density : 08 Nos/Pallet

  • Commonization of 8 Variants

  • Maintaining Strength of the box for stacking

03

Solution

Rotationally Formed, made up of EPP material box which is lighter than other plastic material is been used to manufacture this box.

04

Results

Easy to manufacture

No surface damage on ORVM

Shockproof during transportation

stackability 1+4

Plastic Plugs For Unwanted Painting

Case Study 2

Overview:

In every automotive there are certain areas where panting is not required, because

later on there will be going to assemble a Electrical Component or to apply Sealant for leak proofing. Covering such places by using Masking Tape is tedious and time consuming. Hence Raptech is providing a solution of hiding such areas with Plastic Plugs. These plugs are easy to fit and dispose.

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01

Application

Masking of the unwanted paint at specific areas of a  vehicle.

02

Challenges

  • Location of the areas where plug has to be fits

  • Flexibility at circular or curved portions

  • Limited fitment holes or pockets

  • Repeatability and uniformity with faster deliveries

03

Solution

Raptech has come up with an solution of Plastic Plugs which are manufactured by Vacuum Forming Process. We designed plugs in such a way that protruded portions self lock in holes nearby  the area to hide which made  these easy to fit and remove

04

Results

  • Easy to fit and remove

  • Water, Oil and Corrosion Resistant

  • Speedy process from Prototyping to Production Process