A gentle handling system integrates many differing conveying and transfer techniques to deliver precise, controlled movement to a sports car production line that runs on indexation.
The resurgence in interest in Aston Martin's prestige sports car range is levelled at decisive leadership and innovative ideas that are well executed resulting in new exciting models. This is how the handling system designed and built by Excel Automation for the DB9 final assembly line at Gaydon in Warwickshire can be viewed. The gentle bespoke handling system integrates many differing conveying and transfer techniques to deliver precise, controlled movement to a production line that runs on indexation, spaced at an approximate thirty-five minute tact time, unlike many that operate with conventional paced workflow.

Upon request from Aston Martin's supervisory system, individual car bodies are despatched from a body store and carried into the trim and final assembly area by AGV (Automated Guided Vehicle) where they are transferred onto a jig-slat conveyor.

Prior to being released to final assembly the door and front-end module are removed to allow fitters easier access.

The doors are placed in carriers and conveyed by Excel standard belt driven 500UB Series powered roller conveyor through the door assembly process prior to buffer area to await recall when its matching body arrives at the final assembly stage.

The front-end module is placed on a transfer trolley and these are also buffered and recalled at the final assembly stage.

The jig-slats are installed flush to the factory floor and are coated with a non-slip matt black finish.

The 1000mm wide steel slats are supported on two 30,000lb conveyor chains with inboard rollers and a double flange roller on one side, these chains run on a high carbon wear strip.

During travel on the Excel jig-slat conveyor the interior begins to take shape with electronics, dashboard facias, overhead trim and linings being added to give that elegance we all expect from a prestige car.

The final station is directly below a heavy duty, 240mm deep electrical monorail system, the powered trolleys on this system have a pantograph stabilising system and a body carrier specifically developed by Excel for the Aston Martin DB9 line, a wire rope hoist lowers the carrier which locates on the body.

Pantograph carriers move the bodies through a number of stations when underside trim, drive train and road wheels are fitted.

The pantograph carrier is variable in height, enabling the car body to be raised or lowered according to the work requirements and ergonomics of a particular station.

The body is locked on the pantograph by 'foot turners' - these are rotating supports, one on each arm of the carrier that automatically turn under the car body, as the pantograph raises they slot into defined areas to hold the body in place.

The Excel installation also included the power train assembly and marriage system where the appropriate drive-train, is assembled off-line, with the engine, gearbox, rear sub-axle and front suspension all being aligned on a specially designed fixture trolley.

When complete a powered tug pulls the trolley, guided by a floor rail, to the marriage station.

Here the drive train is raised to meet the car body, the lift design being a key feature as it not only had to be designed to lift both the fixture trolley and the drive tug, it had to be profiled to enable the operators maximum accessibility.

A number of location spigots on guide poles ensure perfect alignment into the vehicle body, allowing fitters to quickly bolt-up the assembly.

Following the fitting of the wheels the virtually finished car is lowered by a four post drop section and sat-down on another Excel slat conveyor - this conveyor has 3000mm wide man riding slats running on 60,000lb conveyor chains and having a depressed slat every 20ft to locate the vehicle wheels.

Final assembly is completed along this slat conveyor including the doors and bumpers originally removed at the start of the cycle, which are recalled from an intermediary buffer location and delivered by an Excel powered roller conveyor for re-mounting to the same body.

The whole materials handling system, the bespoke engineering design, manufacture and superb finish was carried out by Excel Automation at its Worcester plant.