Torque line for suspension
A leading heavy vehicle OEM partnered with Frugalhacks Automation to implement a fully automated assembly and inspection line for suspension sub-systems. This included precision assembly of heavy suspension arms, auto torque applications, and in-line inspection—all integrated into a high-load, servo-controlled line designed for minimal operator intervention.
The project aimed to boost production speed, eliminate manual torque errors, and ensure long-term reliability for critical undercarriage systems in high-load applications.
- Problem Statement
Global Off‑Highway Mining Truck, a leading heavy‑vehicle OEM, faced significant challenges on its manual suspension assembly line:
- Manual torque inconsistencies: Critical torquing up to 2000 Nm relied on human effort, leading to variability and potential safety hazards.
- Labor dependency & safety risks: Operators manually handled and aligned heavy suspension arms—a process that was both slow and dangerous.
- Throughput bottlenecks: Takt time suffered due to inconsistent assembly speeds and manual inspection processes.
- Inspection gaps: Visual inspections were subjective, inconsistent, and lacked digital traceability.
These issues limited scalability, compromised safety, and undermined long‑term reliability. Frugalhacks recognized the need for a fully integrated, high‑torque automated system designed to address these pain points head-on.
- Our Solution
We engineered a fully automated, servo‑driven auto assembly torque line for suspension components from concept to deployment—in just six months, spanning locations in Hosur and India:
- Concept Engineering & Layout
- Designed a linear track with sequential stations for loading, torque, inspection, and unloading eliminating bottlenecks.
- Hydraulic sliding & tilting tables enhanced ergonomics and operator safety.
- Automation & Robotics Integration
- 3-axis servo manipulators precisely held heavy suspension arms.
- 2-axis linear robots ensured efficient part transfer between stations.
- High‑Torque Auto‑Torquing
- Integrated programmable torque units delivering up to 2000 Nm with real-time feedback and traceable logging.
- Eliminated manual error and ensured 100% torque accuracy.
- Vision‑Based Inspection
- In-line auto‑vision system inspected alignment and assembly integrity, flagging defects before final assembly.
- 2-axis linear robots ensured efficient part transfer between stations.
- Control Architecture
- Siemens PLC/HMI managed motion control, torque calibration, safety interlocks, data logging, and changeover recipes.
- Commissioning & Deployment
- Fabricated, built, and tested at Frugalhacks’s India facility.
- Commissioning in Hosur included performance optimization and operator training.
- Tools & Technologies Used
-
Linear Track & Hydraulic Platforms :
Ergonomic support for heavy suspension sub‑systems -
3‑Axis Servo Manipulator :
Precise part handling, reducing human strain -
Auto Vision System :
Real‑time in-line inspection of alignment and defects - Auto‑Torquing System : 2000 Nm programmable torque tools with audits
- 2‑Axis Linear Robot : Fast transfer between stations
- Siemens PLC/HMI : Centralized sequencing, data logging, alarm management
- CAD & Process Mapping : Detailed 3D CAD models, BOMs, and process charts
- Hydraulic Tilting : Ergonomic reorientation of large components
Our system architecture advanced traditional manufacturing practices by integrating high‑load mechanics with digital control boosting reliability, speed, and traceability.
- Results & Conclusion
The introduction of this auto assembly torque line for suspension components delivered transformative outcomes:
- 35% faster cycle times, increasing line throughput substantially
- 100% torque accuracy, logged and verified in real time
- Zero lifting injuries, thanks to servo‑driven handling and hydraulic support
- Improved first-pass yield, with the vision system catching defects early
- Data‑driven operations, with torque, inspection, and cycle data logged for continuous optimization
In short, Frugalhacks’ turnkey system set a new benchmark in heavy‑vehicle suspension production combining safety, precision, and efficiency on a single line.
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