EV Power Distribution and Testing

Project role and responsibilities

Lead Mechanical Engineer


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.