tesla case study

SDC Delivers Semi-Automated Assembly Line for EV Charging System

Semi-Automated Assembly Line for EV Charging System

A leading electric vehicle (EV) manufacturer partnered with SDC to design a reliable, efficient assembly system for its Universal Mobile Connector (UMC) charger. Faced with complex subassemblies, sensitive components, and precise standards, SDC created a semi-automated solution that enhanced production efficiency while ensuring high-quality output.

Technical Components & Technologies

Sensitive electronic PCBs
RFID tracking
O-ring terminal subassembly
Integrated PLCs
tesla case study
tesla case study

Overview

An industry-leading EV manufacturer required a reliable, efficient assembly system for its Universal Mobile Connector (UMC) charger. The project demanded a semi-automated solution capable of handling complex subassemblies, sensitive electronic components, and precise manufacturing standards. Steven Douglas Corp (SDC) successfully designed, built, and integrated a modular assembly system that met these rigorous requirements, enhancing production efficiency and ensuring high-quality output.

Challenges

  • Precision & Complexity: The assembly process involved plastic, metal, and silicone rubber components, as well as sensitive electronic PCBs.
  • Semi-Automation Needs: The system had to balance manual operations with automated processes to maintain flexibility while ensuring repeatability.
  • System Integration: The solution needed to seamlessly incorporate multiple assembly stations, overhead part handling, RFID tracking, and electrical testing.
  • Stringent Quality Standards: The system had to comply with strict safety, ergonomic, and maintenance requirements while ensuring seamless operation.

SDC’s Solution

SDC developed a modular, semi-automated assembly system consisting of:

  • Manually Operated Workstations: Each station was ergonomically designed for operator efficiency and safety.
  • Automated Subassembly Processes: Critical steps, such as O-ring terminal subassembly and electrical testing, were automated for precision and consistency.
  • Advanced Electrical & Control Systems: Integrated PLCs, RFID tracking, and vision systems ensured real-time monitoring and traceability.
  • Custom Tooling & Assembly Fixtures: Designed to handle delicate components while maintaining speed and accuracy.

Results & Impact

  • Increased Production Efficiency: The new system optimized workflow, reducing cycle time and improving throughput.
  • Enhanced Product Quality: Automated inspections and precision tooling minimized defects and ensured compliance with industry standards.
  • Scalable & Future-Ready Design: The modular approach allowed for easy expansion and integration with future automation upgrades.
  • Successful Deployment & Validation: The system passed rigorous on-site testing and acceptance trials, delivering a reliable and robust solution for the EV manufacturer.

Conclusion

By leveraging its expertise in automation and manufacturing, SDC delivered a state-of-the-art assembly system that met the EV market’s high standards. This successful implementation demonstrates SDC’s capability to engineer custom, high-performance automation solutions tailored to modern manufacturing challenges.