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Transfer Case Assembly System

Transfer Case Assembly System


A manufacturer of high mobility multi-purpose wheeled vehicles needed an assembly and material handling system with total flexibility. The main requirement was modification without interruption to production schedules. The Transfer Case Assembly System is a turnkey project that assembles seven different models of transmissions, and has equipment logically arranged for future flexibility.


The equipment was conceived and built with flexibility in mind. Although the Transfer Case Assembly System is extremely large—two buildings were used to assemble the system—each station is capable of being easily modified, re-tooled, re-programmed, even re-used on different lines. The system processes transfer cases with center distances from 204mm to 319mm with a size envelope as large as 600 x 300mm. These dimensions establish a work envelope that the customer expects the equipment to be capable of processing with minimal retooling, on a 20 second floor to floor cycle.

The basic system concept is a combination of power and free systems, dedicated automatic sub-systems, and standalone satellite operations. There are automatic screwdriver stations, pressing operations, oil fill, robotic glue dispense, full functional testing, and two robotic offloads. The control system provides not only operation control but also a higher-level control function of data acquisition and management.

outcomes and benefits

The line will change as better processes are developed and additional models are added. As these demands are made, the system will support the changes without interruption to production.
Highly Flexible Assembly System Processes Parts with Minimal Retooling
Technical Capabilities
Assembly Solutions Dispense Applications Inspection & Testing Material Handling Solutions Robotics Integration Software & Data Integration
Door Hinge Robots 2


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