Assembly Tooling Design & Manufacture

This section showcases the tooling fixtures, component handling and framing structures designed and built by ESA to assist with production assembly. We closely work with our clients to address existing production issues, those linked to awkward component handling, RSI issues and re-tooling machine parts due to product change.


cap1Crank Shaft Trolley

We designed this trolley with the client to provide a suitable method of storing minimum of 12 (hot) engine crank shafts circa 29kg each. The cranks are to be loaded using an existing gripper (temperature of each crank is circa 25 deg but gear is much hotter) after heat treat and then to unloaded locally at assembly line.

Further to the clients brief, the crank will be loaded and unloaded using two different types of grippers and such the trolley must be suitable for both grippers.

The height for the upper layer of crankshafts is to be approximately 1100mm the foot print should be similar to the current stillage and open box. (This is circa 1200 x 1200 with box open)

The trolley must have a retractable towing hitch similar to other trolleys on site and the wheels should be 2 fixed and 2 swivel to allow towing and manual positioning.






From the above requirements we produced this trolley, finished it in RAL7035 powder coasting with ‘Caution Hot Components’ stickers throughout. The trolley was supplied with Chemical Blacked interchangeable component cradles to prevent product contamination.



Engine Flywheel Lock Tool

Our client needed a new locking tool for their next generation engine build, we took the housing model and overlaid our design and checked it against any collisions with the existing process and platen on which the engine block is mounted. The requirement for a this locking tool is mesh the gears together to provide a level of torque reaction when tightening a flywheel to an engine block as the levels of torque seen at the bolt fixings will reach over 150Nm.

cap3The tool needed to be simply locked into place picking up on the flywheel housings existing mounting points and engage the flywheel gear through a timing window. We provided a handle for ease of use.















Fuel Tank Assembly 

Our client required assembly tooling attached to a bench table to allow 2 variants of fuel tanks, 17 and 70 ltr versions to be assembled with all the relevant sub-components, mounting legs, clamping plates, Adblue tank, header unit and several ancillary parts.

This common bench had positions for both size tank modules included in the design. cap7

Both positions could be obtained via rotating the assembly top through 180 degrees on a slew ring. Local toggle clamps kept the work piece in-place whilst the sub-components were fixed into place. A height adjustable top mounted pressure clamp applied positional force to the heater element coupling to allow the element to adhere to the bottom of the tank.cap6














Large Turbo Core Handler/Assistor

Due to varying size range and weight of the product, we were approached to design and manufacture a piece of handling equipment to assist the operator in transferring the turbo core across from a pressing station onto a platen for the remainder of the assembly process.  This Turbo Arm assistor comes with a vertically mounted rotating mast housing a controlled lift cylinder, which forms the main part of the assist arm. The mast is attached to a pair of linear slides that provide a horizontal motion. All movements are controlled in a semi-automatic balanced weight monitored system. The event, loss of air supply does not cause any danger to the operator or surrounding processes as the movements are held in place with air logic, when air is returned an pneumatic soft-start system prevents too much assisted thrust.cap9

This system gave the client a series of ergonomic advantages with a precise, smooth-running linear guided operation coupled with the ability to operate with a varying payload.

cap8The arm is fitted with a dual pressure system to enable the weight to be balanced during the transfer operation and has a pneumatic gripper that locates the part at low pressure to prevent the risk of trapping . Sensors are provided that detect the product but also ensure that the gripper is correctly located before the gripper is actuated. A further sensor will also detect if the gripper is fully clamped before the lift is operated. The station is independently controlled and uses a ‘Handle Start’ function clear of the clamping process to operate the gripper allowing simple use whilst ensuring operator safety. The gripper jaws have profiled guards to shield the movement.



















AWD Differential Assembly Jig and Tool


A new AWD CL Diff assembly jig was designed and manufactured with a requirement to tighten 12 off assembly bolts to torque @ 185 Nm for our client. To facilitate this, a new universal clamping and anti-rotate jig, similar to an existing process was designed. This utilised a stub axle to provide the anti-rotation by engaging with the diff ring gear. A DC tool counts the number of operations for each bolt when running down the bolt to torque, local  local indication provides feedback when part ready. The parts were sensed to check for the correct seating and held in-place with a hand operated clamp. This allowed the operator to use the two-hand trigger to operate the DC Tool, further torque reaction was provided by an Jaeger Handylift 100 (allowing vertical and swivel controlled movements).