Project Overview

Case: Customer demand for an automotive airbag diffuser increased rapidly as vehicles evolved from single driver airbags to driver, passenger, and side curtain systems. Initially, the customer produced the component using manual and semi-automatic processes in Mexico. However, scaling production required additional equipment, floor space, and labor. In addition, ongoing quality issues created further challenges. At this point, the customer approached Tri-Power Design to develop a fully automated solution. They also aimed to reduce manufacturing costs, increase market share, and relocate production from Mexico to the United States.

Solution: Tri-Power Design (TPD) engineered a fully automated system that addressed each of the customer’s concerns while adding new operational benefits. The system delivers a throughput of 4.5 parts per second and requires only a part-time operator. As a result, 8 to 10 employees became available for other tasks. To improve quality, the machine inspects every part and loads finished components directly into shipping cartons with a precise part count.

Replicating the Existing Manufacturing Process

Design Challenges: A primary challenge involved duplicating the existing multi-step manual process. By doing so, the customer avoided re-validating a new manufacturing process, which saved both time and cost. The original process included cutting wire to length, corrugating the wire, wrapping it around a rectangular paddle, forming a slug using a hydraulic press, and pressing the slug into a thimble-shaped housing using a second press.

Dual-Dial Automation Strategy

Another challenge involved forming the slugs and pressing them into housings on a rotary indexing platform. To solve this, Tri-Power Design developed a system with two stacked rotary dials. The upper dial performed the slug forming operation. Meanwhile, the lower dial automatically loaded and positioned the housings directly beneath the forming tool. At the next station, the system pressed the formed slugs through the tooling and into the housings, completing the process efficiently and repeatably.

Call 973.227.8214 or email us today to learn more about the Metex Airbag Filter.