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Global Vehicle Systems Solutions

    The Challenge:

    Design and fabricate a cost effective heavy truck air deflector that would prove strategically beneficial to replace the customers currently used one-piece fibreglass deflector.


    The Solution:

    Global Vehicle Systems designed a 3-piece injection molded air deflector called the G-MADô (global modular air deflector). The injection molded material was used to offer a strong, durable impact resistant structure with a flange design that provides added assembly strength. The substrate was made up of 30% glass filled nylon to give an exact fit to trailer with a taller design eliminating gaps and providing a more aerodynamic profile. The 3-piece design allows for strategic cost savings with smaller and lighter shipping packages, allowing up to 52 fairings per shipment. We reduce future repair cost by designing the G-MADô so if damages occurred to the unit it could be easily serviceable without replacing entire deflector.


    The Challenge:

    The customer approached Global Vehicle Systems with the need of a fully automated assembly cell to install and validate a plurality of clips and a set of foam isolators to a number of automotive door sashes. Besides the complexity of the machine integration, the foam application process involved the challenges of:

    • Having a limited part to part cycle time of 7 seconds
    • Cutting foam isolators into 14 different lengths
    • Splicing the foam ends for uninterrupted cycle
    • Feeding thin foam strips through an accumulator-feed system
    • Synching the respective robot with the correct cut foam length
    • Ensuring accurate separation of the foam liner from the foam
    • Gripping and applying respective foams onto respective parts

    The Solution:

    Global Vehicle Systems designed and manufactured a flexible assembly line with 8 dedicated stations fed by an over/under conveyor system capable of driving 18 pallets that met the required 7 second part-to-part cycle time. Zero downtime is accomplished by using an accumulator assembly and splicing station that allows the operator the time needed to replace a foam roll without interrupting the process. Linear actuators are used in the foam cutting and foam feeding process. Constant tension is required to separate the foam from the liner which is accomplished utilizing a tape gripper assembly. Customized end of arm tooling assemblies, on Fanuc robots, allow accommodating multiple foam lengths. Individual end of arm tooling syncs with the foam-feed assembly which delivers the correct foam length when needed. Programmed robots pick the foam isolators, apply them in the exact position and properly wet out into the partís B-side.

 

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