EV Power Distribution and Testing
Project role and responsibilitiesLead Mechanical Engineer
- Cycle sequence chart
- Managing mechanical design of manual assembly stations completed by internal team members
- Complete mechanical design of test station
- Pneumatic system component selection and schematics
Cycle time: 80 seconds
Project timeline: 26 weeks
The manual assembly line consisting of 10 operator stations produces an assembled EV power distribution module. Station operations vary from component installation, wire harness routing, and fastening.
Once fully assembled, the workpiece carrier shuttles on towards an automatic end-of-line test station. Here the workpiece carrier is positioned and clamped prior to connector plugs at various locations being advanced by pneumatic actuators. Once connected, a test unit provided by the customer is initiated to provide power to each connection point and verify positive continuity. When complete, an OK assembly is shuttled to a mezzanine holding area. NOK assemblies are marked via their RFID pallet tag and routed to a rework area for manual inspection.