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Thames Industrial Estate • Fieldhouse Lane • Marlow • SL7 1TB • United Kingdom 
www.andronhandling.com info@andronhandling...
Jaguar Land Rover JLR Spare wheel Assistor 
Requirements: to pick all variants of spare wheel for L494 (Range Rover sport)...
SLIDE 3
SLIDE 4
CLAMP JAW STRESS CALCULATIONS AND FEA 
SLIDE 5
SLIDE 6
SLIDE 7 
Clamped cross sections through worst 
case spare wheels to be handled 
Outer nylon cone 
extends to allow for the...
SLIDE 8
SLIDE 9
SLIDE 10
Rendered Cross section 
SLIDE 11
SLIDE 12
SLIDE 13 
Rolls Royce Blade C-Scan Assistor 
Requirements: To pick flat pack blades from a “toaster rack” style stillage, ...
SLIDE 14 
SCOPE OF ANDRON SUPPLY 
STAINLESS STEEL 
PARKING STAND 
STAINLESS STEEL 
VACUMM END 
EFFECTOR 
350LB BALANCER, 
...
SLIDE 15 
CORROSION RESISTANT 
ROTATION CYLINDER, 
CLEVISES, AND PIPE 
FITTINGS 
OPERATOR HANDLES WATER RESERVOIR 
STAINLE...
SLIDE 16 
END EFFECTOR PARKED 
JUNCTION BOX
VACUUM ON 
FINGER LEVER 
SLIDE 17 
VACUUM RELEASE 
FINGER LEVER 
ROTATE 2-POSITION 
SWITCH 
VAC OK GREEN 
PNEUMATIC INDICA...
HANDLE MOUNTED 
ON AN ADJUSTABLE 
CLAMP PLATE 
SLIDE 18 
DETENT PLUNGER BUSH 
REPLACABLE STAINLESS 
STEEL WEAR PLATE 
HAND...
SLIDE 19 
VIEW OF HANDLE ROTATION 
STOP BOLT RUNNING IN SLOT 
*ROTATION CYLINDER HIDDEN FROM VIEW IN THIS SCREEN SHOT 
WAT...
SLIDE 20 
WATER CATCHMENT RESERVOIR 
WIRE WOOL 
SILENCER 
Ø8mm BULKHEAD 
ONE TOUCH FITTING 
TOP END CAP 
PIAB INLINE VACUU...
SLIDE 21 
ADJUSTABLE 
ROTATION 
USING 
CYLINDER ROD 
COLLAR 
STAINLESS STEEL 
CYLINDER ROD CLEVIS 
STAINLESS 
STEEL PIPE 
...
SLIDE 22
SLIDE 23 
Jaguar F-Type Coupe Body side assistor. 
Requirements: To pick the F-type coupe aluminium body side panel from a...
SLIDE 24 
Requested cross shop steel work to be added 
Existing Rivet gun down shop rail 
Air supply point: 
1/2” BSP Fema...
SLIDE 25 
Storyboard
SLIDE 26 
Storyboard
SLIDE 27 
Storyboard
SLIDE 28 
Storyboard
SLIDE 29 
Storyboard
SLIDE 30 
AutoCAD Layout Overlay
Pick Controls 
SLIDE 31 
Vac ok 
pneumatic 
indicator 
Vac on levers 
Brakes on/off 
push button 
lever 
Junction box 
wit...
Place Controls 
SLIDE 32 
Vac ok 
pneumatic 
indicator 
Release push 
button lever 
Brakes on/off 
push button 
lever 
Rel...
Rotate Controls 
Rotate to place 
position push 
button lever 
SLIDE 33 
Rotate to pick 
position push 
button lever 
Vac ...
SLIDE 34 
Elephants Trunk 
nylon Vac cup 
locator
SLIDE 35 
Adjustable 
rotation stop 
Adjustable rotation 
stop - adjustable 
from 0° to 190°
Control Scheme 
• Press ‘brake’ lever on pick controls to release brakes 
• Manoeuvre assistor over to the part in the sti...
SLIDE 37
SLIDE 38
SLIDE 39
L538 (Evoque) and L550 (Freelander 3) Axle Lifter 
Requirements: Design a frame manually operated lifting frame to pick th...
SLIDE 41
SLIDE 42
SLIDE 43 
L550 proposed pick point
SLIDE 44
SLIDE 45
SLIDE 46
SLIDE 47
Stress Calculations and FEA 
SLIDE 48
Final Design after calculations 
SLIDE 49
SLIDE 50
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Andron design portfolio final

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

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Andron design portfolio final

  1. 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. 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. 3. SLIDE 3
  4. 4. SLIDE 4
  5. 5. CLAMP JAW STRESS CALCULATIONS AND FEA SLIDE 5
  6. 6. SLIDE 6
  7. 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. 8. SLIDE 8
  9. 9. SLIDE 9
  10. 10. SLIDE 10
  11. 11. Rendered Cross section SLIDE 11
  12. 12. SLIDE 12
  13. 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. 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. 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. 16. SLIDE 16 END EFFECTOR PARKED JUNCTION BOX
  17. 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. 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. 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. 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. 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. 22. SLIDE 22
  23. 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. 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. 25. SLIDE 25 Storyboard
  26. 26. SLIDE 26 Storyboard
  27. 27. SLIDE 27 Storyboard
  28. 28. SLIDE 28 Storyboard
  29. 29. SLIDE 29 Storyboard
  30. 30. SLIDE 30 AutoCAD Layout Overlay
  31. 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. 32. Place Controls SLIDE 32 Vac ok pneumatic indicator Release push button lever Brakes on/off push button lever Release push button lever
  33. 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. 34. SLIDE 34 Elephants Trunk nylon Vac cup locator
  35. 35. SLIDE 35 Adjustable rotation stop Adjustable rotation stop - adjustable from 0° to 190°
  36. 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. 37. SLIDE 37
  38. 38. SLIDE 38
  39. 39. SLIDE 39
  40. 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. 41. SLIDE 41
  42. 42. SLIDE 42
  43. 43. SLIDE 43 L550 proposed pick point
  44. 44. SLIDE 44
  45. 45. SLIDE 45
  46. 46. SLIDE 46
  47. 47. SLIDE 47
  48. 48. Stress Calculations and FEA SLIDE 48
  49. 49. Final Design after calculations SLIDE 49
  50. 50. SLIDE 50

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