Project Showcase

Steering Wheel Assembly & EOL Testing Station

Dedicated assembly and end‑of‑line testing station for automotive steering wheels – integrating fastening, switch testing, and barcode traceability in a 55‑second cycle.

Project Overview

Precision Assembly & EOL Testing for Steering Wheels

A dedicated Steering Wheel Assembly and End‑of‑Line (EOL) Testing Station designed for efficient and reliable assembly of automotive steering wheels. The system integrates precision fastening, steering wheel positioning, electrical switch testing, and barcode identification into a streamlined production process.

The workstation supports consistent assembly quality while maintaining a cycle time of 55 seconds per component, making it suitable for high‑volume automotive manufacturing environments.

Customer: TRW Sun Steering Wheel India Pvt. Ltd., Pirangut, Pune, Maharashtra.

Steering Wheel Assembly Station
Key Design Elements

Integrated Workstation Features

Aluminium Station Frame

Robust and ergonomically designed workstation structure that provides stability and operator comfort.

  • Lightweight yet rigid
  • Modular construction
  • Optimised for operator access

Steering Wheel Tilt Fixture

Provides accurate positioning and accessibility during assembly operations, ensuring correct orientation for fastening and testing.

  • Tilt mechanism
  • Quick clamping
  • Repeatable positioning

DC Screwdriver System

Controlled fastening system for consistent and repeatable screw tightening, with torque monitoring.

  • Adjustable torque
  • Auto‑shutoff
  • Data logging capability

EOL Switch Testing

Automated end‑of‑line testing to verify steering wheel switch functionality, ensuring every unit meets specifications.

  • Electrical continuity test
  • Functional verification
  • Pass/fail indication

Barcode Printing & Traceability

Product identification and traceability through barcode generation and printing for each assembled steering wheel.

  • Unique serialisation
  • Print & apply
  • Integration with MES

55‑Second Cycle Time

Optimised production flow designed for high‑volume automotive manufacturing, achieving a cycle time of 55 seconds per component.

  • Balanced operations
  • Minimal idle time
  • Consistent throughput
Built for Performance

Key Capabilities of the Assembly Station

PLC & HMI automation
Servo & pneumatic actuation
Sensor‑based switch testing
Safety interlocks & guards
Barcode generation & traceability
55‑sec optimized cycle time
Ergonomic tilt fixture
Repeatable fastening torque
Data logging & MES interface
Our Process

Machine Development Process

01
Application Study

Understanding the product, manufacturing process, production volume, and customer requirements.

02
Concept Development

Developing a suitable machine concept based on the application and required automation level.

03
Mechanical & Automation Design

Machine structure, mechanisms, tooling, electrical systems, PLC controls, sensors, and components.

04
Manufacturing & Assembly

Fabrication, assembly, integration, and testing according to the approved design.

05
Testing & Validation

Complete machine trials to verify functionality, cycle time, accuracy, safety, and repeatability.

06
Installation & Support

Installation and commissioning at the customer's facility with required technical support.

Key Benefits

Why This Assembly Station?

High‑precision steering wheel assembly – accurate positioning and fastening.
Consistent and repeatable fastening – with torque monitoring.
Integrated EOL functional testing – verifies switch performance.
Product‑level barcode traceability – ensures full traceability.
Ergonomic workstation design – improves operator efficiency.
Reduced manual inspection requirements – automated testing.
Suitable for high‑volume automotive production – 55‑sec cycle.
Optimized 55‑second production cycle – meets throughput targets.
Project Details

Customer & Application

  • Customer: TRW Sun Steering Wheel India Pvt. Ltd.
  • Location: Pirangut, Pune, Maharashtra
  • Component: Steering Wheel
  • Cycle Time: 55 seconds / component
  • Application: Steering Wheel & Switch Assembly + Testing

Why Tri-Dot Solution?

Combining mechanical engineering, automation, precision tooling, and inspection to deliver complete SPM solutions that are reliable, efficient, safe, and easy to operate.

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