Summary
Key results
Complete design package for 2 automated stations
Faster delivery without additional recruitment
Additional design capacity for 4 assembly lines
AuE Kassel GmbH was delivering a project covering 4 front and rear axle assembly lines for electric vehicles. The stations had to handle 12 bolting points in a defined sequence within a 59-second cycle time. Limited space and the need to ensure service access added further design constraints.
The client required qualified engineering support to develop concepts, 3D models as well as detailed design and process documentation compliant with its internal standards based on ISO requirements. The deliverables had to be complete and ready for direct use in component manufacturing, machine assembly, and commissioning.
Another key requirement was to increase design capacity without hiring additional specialists. The client needed a team that could deliver the agreed scope for selected stations while also supporting the preparation of 2D documentation for the remaining assembly stations.
Mechanical design from concept through commissioning support
Over approximately 5–6 months, the Sii Poland team, comprising a Delivery Manager, Team Leader, and 4 Mechanical Design Engineers, delivered the agreed design scope for the assembly stations. The work included approximately 2 000 hours of engineering design plus an additional 750 hours dedicated to preparing 2D documentation.
The scope included:
- Developing 2 technical concepts before preparing the final 3D design
- Delivering the complete 3D design for 2 automated stations for fastening suspension components
- Designing machine frames, components for gripping and positioning the axle during fastening, screw feeders, linear drive systems with nutrunners, and safety guarding
- Completing approximately 30% of the design for a robotic station, including the subframe, axle gripping, and positioning components, linear drive systems with nutrunners and robot end-of-arm tooling
- Preparing 2D documentation covering geometric dimensioning and tolerancing, material selection and finishing methods in line with the client’s internal standards based on ISO requirements
- Supporting the preparation of 2D documentation for the remaining assembly stations
- Preparing bills of materials for all assemblies and complete stations
- Developing a timing diagram showing operation times and sequences, a process flowchart, a list of control components as well as presentations of the concept and final design
- Carrying out the design work in SolidWorks using Citrix and Microsoft Teams
- Supporting design changes during machine commissioning in cooperation with PLC programmers and robotics engineers
Sii Poland delivered the agreed scope from functional concept and mechanical design through the documentation required for machine manufacturing and assembly, then supported the implementation of necessary changes during commissioning.
Complete design package and greater delivery flexibility
AuE Kassel GmbH received a consistent package covering technical concepts, 3D models, 2D documentation, bills of materials, and process documentation. The deliverables were used directly for component manufacturing, machine assembly, and commissioning, allowing the project to move from the design phase into execution based on complete engineering data.
Sii’s involvement increased the client’s available design capacity and helped shorten delivery time without the need to hire additional specialists. Support during commissioning also enabled the necessary design changes to be introduced in cooperation with PLC programmers and robotics engineers.
Key results
- Complete designs for 2 automated fastening stations
- Approximately 30% of the robotic station design completed
- Approximately 2 000 hours of design work and 750 hours of 2D documentation preparation
- Documentation used for component manufacturing, machine assembly, and commissioning
- Faster delivery without additional recruitment