Various Assistors I designed for Jaguar Land Rover Rolls Royce for use in their assembly lines during manufacture

1. Thames Industrial Estate • Fieldhouse Lane • Marlow • SL7 1TB • United Kingdom
www.andronhandling.com info@andronhandling.com 0845 075 8211
Design Portfolio
APRIL 2014

2. Jaguar Land Rover JLR Spare wheel Assistor
Requirements: to pick all variants of spare wheel for L494 (Range Rover sport) X760 (new jaguar XE) and X761 (new Jaguar SUV), 8
spare wheel variants in total ranging from a 20” alloy full size spare, to a pressed mild steel space saver spare. Wheels to be picked
up horizontally from a delivery stillage and transferred into the rear of the relevant vehicle.
SLIDE 2

3. SLIDE 3

4. SLIDE 4

5. CLAMP JAW STRESS CALCULATIONS AND FEA
SLIDE 5

6. SLIDE 6

7. SLIDE 7
Clamped cross sections through worst
case spare wheels to be handled
Outer nylon cone
extends to allow for the
difference in internal
wheel bore diameters.
Central pin extends to open the
jaws, and retracts to close the
jaws, the clamp jaws are
mechanically locked in each
position so it will not drop the part
in the event of complete and
sudden air failure.

8. SLIDE 8

9. SLIDE 9

10. SLIDE 10

11. Rendered Cross section
SLIDE 11

12. SLIDE 12

13. SLIDE 13
Rolls Royce Blade C-Scan Assistor
Requirements: To pick flat pack blades from a “toaster rack” style stillage, rotate it 90° and place it submerged
in a water tank for the Rolls-Royce C-scan procedure to take place. The C-Scan is an ultrasonic scan of the
blade to check for impurities / defects / contaminants in the metal blades. Once the scanning operation was
complete, the assistor would then pick the submerged blade up out the C-scan tank, rotate by 90° and back
into the stillage.
The assistor was to handle all blades from all the Rolls-Royce engines from the Trent 500 to the Trent XWB , 8
variants in total with a maximum safe working load of 65kgs.
A few design requirements had to be considered before the design could begin:
• How would the performance of the pneumatic vacuum generator be affected when water is introduced into
the system?
• How would the vacuum cup performance be affected when picking up in a water filled environment.
• This was a very corrosive environment so the end effecter was to be made of stainless steel, all pneumatic
fittings were to be stainless steel, pneumatic cylinders were to be corrosions resistant, clean room and food
industry standard.
• To avoid any contaminants entering the C-scan tank all bearings and bushes had to be sealed and no oilite
bushes to be used.
• No silicone based materials were to be in contact with the blade, a nitrile-pvc vacuum cup from PIAB was
chosen.

14. SLIDE 14
SCOPE OF ANDRON SUPPLY
STAINLESS STEEL
PARKING STAND
STAINLESS STEEL
VACUMM END
EFFECTOR
350LB BALANCER,
KBK2 TROLLEYS AND
PNEUMATIC CABINET
ASSEMBLY

15. SLIDE 15
CORROSION RESISTANT
ROTATION CYLINDER,
CLEVISES, AND PIPE
FITTINGS
OPERATOR HANDLES WATER RESERVOIR
STAINLESS STEEL
PARKING STAND
PIAB F 150 NITRILE
PVC VACUUM CUPS
C-SCAN END EFFECTOR
STAINLESS STEEL LIFT EYE
90° ROTATION

16. SLIDE 16
END EFFECTOR PARKED
JUNCTION BOX

17. VACUUM ON
FINGER LEVER
SLIDE 17
VACUUM RELEASE
FINGER LEVER
ROTATE 2-POSITION
SWITCH
VAC OK GREEN
PNEUMATIC INDICATOR
END EFFECTOR CONTROLS
PARKING BRAKE 2-
POSITION SWITCH
ZA PROPORTIONAL
LIFT CONTROLS
VAC ON AND
RELEASE ENABLE
FINGER LEVER
DETENT
PLUNGER
HANDLE
ROTATION
STOP BOLT
FULL STAINLESS STEEL
CONSTRUCTION
RUBBER HANDLE GRIPS

18. HANDLE MOUNTED
ON AN ADJUSTABLE
CLAMP PLATE
SLIDE 18
DETENT PLUNGER BUSH
REPLACABLE STAINLESS
STEEL WEAR PLATE
HANDLE ROTATION STOP
BOLT RUNS IN SLOT AND
ELIMINATES FINGER TRAP
HANDLE AND RESERVOIR
MOUTING

19. SLIDE 19
VIEW OF HANDLE ROTATION
STOP BOLT RUNNING IN SLOT
*ROTATION CYLINDER HIDDEN FROM VIEW IN THIS SCREEN SHOT
WATER RESERVIOR HELD IN PLACE
WITH STAINLESS STEEL TUBE CLAMP,
FOR ADJUSTMENT AND EASE OF
REMOVAL
WATER RESERVIOR
HANDLE AND RESERVOIR MOUTING

20. SLIDE 20
WATER CATCHMENT RESERVOIR
WIRE WOOL
SILENCER
Ø8mm BULKHEAD
ONE TOUCH FITTING
TOP END CAP
PIAB INLINE VACUUM
GENERATOR
2 x ELBOW
3” x 1.5mm STAINLESS
STEEL TUBE
ATTACHMENT
SCREWS
BOTTOM END CAP
WIRE WOOL
SILENCER

21. SLIDE 21
ADJUSTABLE
ROTATION
USING
CYLINDER ROD
COLLAR
STAINLESS STEEL
CYLINDER ROD CLEVIS
STAINLESS
STEEL PIPE
FITTINGS
ALL FINGER TRAP POINTS
HAVE BEEN REMOVED AT
ROTATION JOINT
90° VACUUM CUP ROTATION AND MOUNTING
STAINLESS STEEL THREADED
VACCUM CUP MOUNTING
SHAFT

22. SLIDE 22

23. SLIDE 23
Jaguar F-Type Coupe Body side assistor.
Requirements: To pick the F-type coupe aluminium body side panel from a delivery stillage, rotate it through 90° and
place on to the f-type coupe Body in white frame ready for the riveting/welding process to take place further down the
line.
One assistor on each side of the line for left and right hand side body panels.
Picking up on the body panels A-surface, care had to be taken to prevent any A-surface from being contacted by
anything other than soft nylon, polyurethane and rubber.

24. SLIDE 24
Requested cross shop steel work to be added
Existing Rivet gun down shop rail
Air supply point:
1/2” BSP Female
with Ball Valve
Customer to supply
New assistor down shop rail 5m length
Existing Rivet gun cross shop rail
Air supply point:
1/2” BSP Female
with Ball Valve
Customer to supply
Alternative option pending reach calculations:
Extend rivet gun down shop rail and run body side assistor carriage in the same down
shop rail.
Layout

25. SLIDE 25
Storyboard

26. SLIDE 26
Storyboard

27. SLIDE 27
Storyboard

28. SLIDE 28
Storyboard

29. SLIDE 29
Storyboard

30. SLIDE 30
AutoCAD Layout Overlay

31. Pick Controls
SLIDE 31
Vac ok
pneumatic
indicator
Vac on levers
Brakes on/off
push button
lever
Junction box
with pneumatic
balance trim
adjuster knob

32. Place Controls
SLIDE 32
Vac ok
pneumatic
indicator
Release push
button lever
Brakes on/off
push button
lever
Release push
button lever

33. Rotate Controls
Rotate to place
position push
button lever
SLIDE 33
Rotate to pick
position push
button lever
Vac ok
pneumatic
indicator
Brakes on/off
push button
lever
Enable push
button lever

34. SLIDE 34
Elephants Trunk
nylon Vac cup
locator

35. SLIDE 35
Adjustable
rotation stop
Adjustable rotation
stop - adjustable
from 0° to 190°

36. Control Scheme
• Press ‘brake’ lever on pick controls to release brakes
• Manoeuvre assistor over to the part in the stillage and visually locate assistor to the part using the nylon locators
as guides.
• When satisfied that it is located, press both ‘Vac on’ finger levers to switch on the vacuum circuit
• When a successful vacuum has been reached the ‘Vac ok’ indicator will illuminate and automatically switch the
assistor into the higher balanced load. Use ‘balance’ knob to adjust the balance trim as necessary.
* NB - If the part is not correctly located in the assistor it will not generate a successful vacuum, the ‘Vac ok’ indicator
will not illuminate and the assistor will not switch to Load.
• Carefully remove the Assistor and component from the stillage and manoeuvre into a clear space ready for
rotation.
• Press ‘brake’ brake lever to apply brakes and move into position in front of rotate handles.
• If necessary press brake lever from rotate handles to release brakes and readjust assistor position as necessary to
clear any potential obstacles, then apply brakes again when you are satisfied all obstacles are clear.
• From rotate handles press the ‘enable’ lever along with ‘rot right’ lever to rotate part from pick to place position.
* NB – Brakes should be applied during the full rotation of the part to avoid assistor drifting into build fixture or
stillage.
• Move into position in front of place handles, press the brake lever to release the brakes again and locate the part
in the build fixture.
• Once located, press both release levers to switch off the vacuum circuit and release the part, this will
automatically switch the assistor back to the lower balanced load.
• Move assistor to safe or parked position for repeat operation.
SLIDE 36

37. SLIDE 37

38. SLIDE 38

39. SLIDE 39

40. L538 (Evoque) and L550 (Freelander 3) Axle Lifter
Requirements: Design a frame manually operated lifting frame to pick the fully assembled axle assembly from build
fixture and transfer over to marriage tug using existing Demag electric hoist and existing overhead trackwork. There was
no pneumatics in the axle build area so any clamps had to be manually operated.
SLIDE 40

41. SLIDE 41

42. SLIDE 42

43. SLIDE 43
L550 proposed pick point

44. SLIDE 44

45. SLIDE 45

46. SLIDE 46

47. SLIDE 47

48. Stress Calculations and FEA
SLIDE 48

49. Final Design after calculations
SLIDE 49

50. SLIDE 50