Strength analysis of mobile assembly line components: ensure durability and efficiency in Automotive manufacturing.

At Endego, we specialize in advanced engineering and help manufacturers validate and optimize their production equipment, often through computer simulations. In a recent collaboration with an automotive industry Client, Endego team of strength specialists used CAE virtual validation tools and conducted a comprehensive analysis of key mobile assembly line elements to ensure they meet strict performance and safety criteria.

Project challenge: find the best compromise between strength and stiffness under the limited mass weight of the components

The client requested a structural assessment of key components used in mobile assembly lines:

• grippers,
• adapters,
• consoles,
• carriages for the transport of car bodies and assemblies.

These elements are subjected to high accelerations and mechanical stresses, and deformations, which can affect either their durability or operational efficiency. The challenge was twofold:

1. Assess whether the components could withstand the required stresses under dynamic loads.
2. Optimize their design in cases where the strength or deformation criteria are not met, and so provide improved reliability without unnecessary mass weight increase.

The goal was to enhance operational safety, extend component lifespan, and optimize manufacturing precision.

Our approach: advanced FE simulations & structural optimization

To meet the Client’s requirements, the Endego CAE Virtual Validation team applied the analysis by the Finite Element Method (FEM) to evaluate and optimize the mobile assembly line components.

Key steps in the analysis:

1. Creation of FE models for individual components and sometimes MBD models:
   • Each gripper, adapter, console, and carriage was modeled based on geometry, with detailed material properties and connection representations.
   • Bolted and welded joints were depicted to capture their behavior under real-world conditions.
2. Stress distribution and deformation assessment:
   • The simulation models were subjected to operational acceleration patterns and mechanical forces to determine stress distribution, deformations, and potential failure locations.
   • Connection joints and mounting points were assessed to ensure structural integrity during long-term operation.
3. Component optimization:
   • In collaboration with the Client’s engineering team, Endego strength specialists identified areas requiring reinforcement or redesign.
   • The optimized component structures maintain strength, durability, and working precision while ensuring technological feasibility and ease of manufacturing.

By utilizing simulation-driven design validation, Endego ensured that all components meet stringent safety standards while maintaining optimal performance.

Project Outcome: Safe and Reliable Components for Mobile Assembly Lines

The strength-optimized components, as analyzed and verified by the Endego engineering team, provide long-term durability and failure-free operation.

The key benefits for the Client include:

• Increased production capacity for mobile assembly lines in the automotive sector.
• Improved reliability and safety of key manufacturing components.
• Expanded cooperation with a major automotive manufacturer and strengthened position in the industry.

By ensuring that all grippers, adapters, consoles, and carriages meet the required stress and deformation criteria, Endego helped the Client to enhance production efficiency, minimize maintenance downtime, and ensure consistent manufacturing quality.

At Endego, we provide structural optimization by CAE virtual validation services for automotive manufacturing, industrial automation, and mechanical engineering applications. Our expertise in FE modeling, stress analysis, and dynamic load simulations enables manufacturers to build robust, efficient, and scalable production systems.

If your company is looking for engineering support in structural validation, dynamic load assessment, or component optimization, contact us today! Our team is ready to help you enhance manufacturing reliability and performance.

📩 Get in touch with us to discuss your project.