Automated Windshield Lift
Led the design, assembly, testing, and commissioning of an automated windshield lift system at an automotive plant. Directed the engineering and implementation of a solution that positions windshields for optimal operator handling, enabling precise lifting and placement onto vehicles. The system improved assembly efficiency and operator ergonomics.
Design
Led the design of the system in SolidWorks, including multiple site visits to take measurements and collaborate with operators to optimize functionality. The system integrates eight linear actuators mounted on a turntable, coordinated through a central control system and triggered by sensors to raise windshields into an ergonomic position for installation. Custom sheet metal brackets and machined clamps were designed to secure the actuators, ensuring precise, reliable, and safe operation.
Assembly and Setup
The system was fabricated using powder-coated, custom-formed sheet metal mounting brackets and CNC-machined clamps for the linear actuators. Specialized rubber bumpers were installed on the actuators to interface safely with the windshield. I led the full assembly of all components, including mounting brackets, clamps, sensors and sensor brackets, control boxes, and the electrical enclosure. The existing turntable system was modified to integrate the windshield lifting mechanism, and I completed all electrical connections, linking sensors and actuators to the control cabinet and operator button interfaces.
Testing
I led the testing and commissioning of the windshield lift system after installation, fine-tuning both the linear actuators and sensors. Using potentiometers in the control cabinet, I set the starting and final heights for each of the eight actuators, adjusting and testing them individually to ensure smooth, synchronized movement. The system now allows the operator to position the lift device, automatically raise the windshield to an ergonomic height for handling, and then lower it for the next cycle, providing reliable and efficient operation on the assembly line.