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Production: ZEV Main Battery Marriage

Full automation cell receiving main batteries on their delivery pallets, post testing, capturing their location to an initial standard and onward transporting to the marriage (insertion) station via AGV (Autonomous Guided Vehicle). In the marriage station the BIW is captured and locked, and the battery undergoes multiple final location steps, ending with a geo-standard, as it rises into final position for manual securing.

Competencies

• Structural design

• Tooling/Production Equipment design

• BIW Design Codes & Standards

• Machinery Safety

• System integration

• Process engineering

• Team & partner working

• Development, Simulation, Analysis & TAKT

• Project, Contract & Commercial Management

SPM: Automated Coil Former

Fully automated, intelligent coil forming machine; self adapting to wire gauge, coil designs, sizes and types. Accurate to 0.012mm, this version is for smaller gauges of wire however the design is entirely scalable. Being fully electric, this machine is optimized for high-rate production - up to 750 units per hour, with low energy consumption and is fully enabled to interface with production control architectures.

Competencies

• Problem solving

• Research, development & simulation

• Process engineering

• Design-For-Manufacture-and-Use (DFMU)

• Material handling & forming

• Machine integration

• Ergonomics and machine safety

• Upstream control I/O and live data delivery

Portfolio

Automated Coil Former

Logistics Handling Suite

Non-marring Hydraulic
Separator

HEP Debris
Screening Gate

Composite Process Dryer

R&D: Telescopic Spray Boom

A single-sided, hydraulic folding & telescoping agricultural spray boom. Optimised for a standard class 2 hitch (or higher) and utilising our structural design & structural bonding expertise.

Careful attention to phasing and process enables spraying of crop at variable boom extensions, with tight limits on both weight and packaging space in operation and storage being critical challenge points.

Competencies

• Structural design

• Equipment design

• Hydraulic design (oil and water)

• Research, innovation & experience

• Machinery Safety

• System integration

• Process engineering

• Metallurgy, Chemistry & Bonding

• Development, Simulation & Analysis

• Project Management

Production: Logistics Handling Suite

A suite of robust, accurate, dedicated clamping and controlled manipulation devices to secure high value component assemblies for prolonged transportation. Fully complaint with manual handling limits and assisting manipulation and installation of the delivered assembly at the final assembly location.

Competencies

• Problem solving, lateral thinking

• Research and simulation

• Creation and control of complex geometries and constraints

• Design-For-Manufacture-and-Use (DFMU)

• Material understanding; particularly mass, strength and fatigue

• Process integration

• Ergonomics and operator safety (international compliance)

Production: Composite Process Dryer

Automated and integrated between production steps, this PTFE belt-based dryer is temperature and speed regulated to optimize the drying of the payload within its own length. Fully adaptable, independently controlled heat zones coupled with accurate transit rate control provide flexibility to adapt in real time to ensure the output moisture level is achieved for the following stage.

Competencies

• Understanding need, extrapolating and cross-pollination

• Research, virtual development & simulation

• Design-For-Manufacture-and-Use (DFMU)

• Material affinity; particularly behaviour projections

• Process & machine integration

• Ergonomics, machinery and operator safety

• Project management and support

Production: Non-marring Hydraulic Separator

Portable, manually operated, synchonised hydraulic splitter providing mechanically collaborative organic work-holding without marring contact surfaces or finishes. Integrated into an existing process and existing equipment to ensure reuse of expensive composite component sections and minimise waste and cost to the end customer.

Competencies

• Experience based material selection

• Reduction of part count and ‘adding lightness’

• Kinetic energy translation and deployment

• Mechanical and Hydraulic Design Engineering

• Design-For-Manufacture-and-Use (DFMU)

• Process & machine integration

• Ergonomics, manual handling and operator safety

R&D: HEP Debris Screening Gate

Working with natural forces rather than against, this design project enables screening of river borne debris from the main flow and preventing physical and economic harms to the sensitive generation equipment.

Briefed to cater for everything from whole trees and personal watercraft to stray swimmers and litter, as well as featuring dynamic adaptation to the seasonal waterlines and flood/drought conditions, the solution has a self clearing mode that is fully remotely commanded and monitored.