For an electric vehicle motor manufacturer, installing coolant O-rings inside the motor housing was a delicate and repetitive task. The challenge was to ensure damage-free O-ring installation while maintaining tight tolerances and high throughput. Our goal was to automate the process using as many standard components as possible, keeping the system cost-effective, quiet, and reliable.
The key challenge lay in avoiding nicks, scratches, or deformation of the O-rings during installation. The O-rings had to slide over the sharp edge of the coolant jacket bore — a step that previously led to frequent sealing failures and leak issues. At the same time, the design had to:
Our design philosophy centered around simplicity, modularity, and precision.
Standardization: Wherever possible, we used catalog components instead of custom machining. Even custom brackets and frames were made from simple plate geometries to reduce manufacturing complexity.
Actuator Selection: We performed in-depth force and speed calculations to correctly size the actuators — balancing performance and cost.
Low-Noise Design: To minimize operating noise, we prioritized electric actuators from Festo and limited the use of pneumatics to only where necessary.
O-Ring Rack System: Designed a quick-swap rack allowing the operator to preload 40–50 O-rings at once. This minimized downtime and improved ergonomics.
Explore our other projects as well – High-Speed Motoring Test Bench
Key Learning: Designing with simplicity in mind — using standard parts, simple geometries, and well-sized actuators can achieve high precision and reliability without unnecessary complexity or cost. Balancing cost, performance, and ergonomics early in the design phase proved critical to project success.
Note: Certain images and mechanical details have been modified to maintain client confidentiality.
