Wheel Hub Manipulator
The Wheel Hub Manipulator project involved reverse engineering a non-functional assembly-line device and redesigning it to improve ergonomics and efficiency. I led the redesign, assisted in assembly, and conducted functional testing to validate the updated system.
Design
An original device, fabricated without formal engineering or ergonomic considerations, was received in a state of disrepair. It had been used line-side on an automotive assembly line to lift and position wheel hubs onto buses. Measurements were taken from the existing device and the wheel hub dimensions, and a new system was designed in SolidWorks using welded tubular steel and bent sheet metal to optimize efficiency. The design incorporates an adjustable center of gravity, ergonomically positioned operator handles, bearings for smooth rotation, and high-force linear clamps to securely grip the wheel hub.
Manufacturing
The device was fabricated from welded high-strength steel tubing and laser-cut, formed sheet metal. The lightweight tubing enhanced overall ergonomics. Assembly was completed in-house, integrating fasteners, bearings, handles, shackles, hooks, and load-rated components. The finished system was painted safety yellow and labeled with load-rating decals.
Testing
The wheel hub manipulator was tested with various hub sizes. The device was mounted on an electric hoist and positioned over each hub. Hubs were secured using the linear clamps, and the hoist was raised to lift them. Hub rotation was evaluated, and the center-of-gravity adjustments were fine-tuned to ensure smooth, balanced rotation along the hub axis.