While working at A's Precision I was challenged with the task to design and manufacture many on the floor part testing gauges. These gauges were used constantly on the shop floor to test almost every part that came off the production. This meant that the gauges needed to be designed with the concept of serviceability in mind. Every minute a part was not being tested meant the company was losing money.
Figure 1: Transmission Ring Production GO / NO GO Gauge
Figure 2: Transmission Ring Production GO / NO GO Gauge
The above gauges were both iterated to allow for faster testing. Initially the gauges featured Mitutoyo sensors that only had an analog feedback. I took it upon myself to source a new set of Mitutoyo sensors that had a red and green feedback screen. This allowed the operator to have a visual feedback as opposed to reading the sensor.
I also was challenged with the task of adding an additional sensor to make sure each part was manufactured on the correct side of the work piece. This was accomplished by adding a fourth sensor to the left hand side of the gauge to test if the machined part did not have an unwanted chamfer.
Figure 3: Motor Assembly Fit Gauge
This motor testing gauge was used to make sure that correct bolt-hole pattern was machined on a motor mount. It featured two ergonomic handles to allow for easier use by the operator.
Figure 4: Block Multi-Position Gauge
This was the first gauge I designed while at A's it features 4 Mitutoyo linear sensors that would measure the part at 4 locations, this saved the operator tedious work and valuable time. The work piece would sit on 4 hardened steel rest pins, this made sure it was perfectly flat and had a solid reference point.
Figure 5: Slide Gauge Featuring a GO and NO GO Gauge
This gauge was designed near my final week of work so I did not get the opportunity to see it get implemented. The device tested the transmission rings pictured in Figure 1 & 2. It has two opposite facing height gauges. The left gauge is placed a fraction of an inch lower than the right height gauge. This meant if the part fit in one of the height gauges it was correctly machined but if it did not fit in either it was the wrong size and would need to be re-worked or scraped.
Figure 6: Hydraulic Multi-Clamp Fixture
This hydraulic swing-clamp fixture was also designed near the end of my term, so I did not get the chance to see it get implemented. It features 3 hydraulic swing clamps that would hold the work piece, as well as 2 hydraulic positioning clamps.
