Automotive Fixtures, Test Rigs and Leak Test Machines

Equipment that keeps automotive lines on takt

Automotive suppliers work to tight takt times, PPAP approval and zero-defect expectations. Fixtures must locate parts repeatably for thousands of cycles, test machines must catch every leak without false rejects, and handling aids must protect finished surfaces. LTM designs this equipment for tier 1 and tier 2 suppliers and for the machine builders who serve them.

Automotive equipment we design

• Assembly fixtures and welding fixtures with hardened locators and quick clamping
• Leak and pressure test machines for castings, housings and pump bodies
• End-of-line test rigs and functional testers
• Inspection fixtures and gauges with poka-yoke features
• Part handling, loading aids and low-cost automation for small suppliers
• Part feeding systems for assembly cells

From part drawing to production fixture

A typical fixture project starts with the part drawing and the customer's datum scheme. We define the locating points to match those datums, choose clamp positions that hold the part without distortion and check access for welding torches, tools or measurement probes. A concept with the locating and clamping scheme is reviewed with you before detail design, since this is where most fixture quality is decided.

Detail design follows with hardened, replaceable locators, standard clamps, sensor positions for part presence and clamp confirmation, and error proofing so the part can only be loaded the correct way. Drawings include the locator tolerances needed to meet your measurement system requirements, ready for a toolroom to build and certify.

For leak test and functional test machines the same approach is applied to sealing and clamping: seals are designed so they do not damage machined faces, clamp forces are calculated against test pressure with margin, and test sequences are timed against line takt so the tester never becomes the bottleneck on the line.

Design principles for automotive fixtures

3-2-1 location: fixtures use a clear datum scheme matched to the part drawing so measured results agree with the customer's inspection. Error proofing: parts that can be loaded wrongly are prevented by geometry, not by operator attention. Wear and maintenance: locators and clamp pads are replaceable standard parts. Ergonomics: loading height, clamp force and reach are designed for operators working a full shift. Cycle time: clamping and test sequences are timed against line takt before detail design.

Leak testing experience

LTM designed a water leakage testing machine for centrifugal pump casings that detects blow holes and seal leaks and accepts more than 13 casing variants with quick changeover. The same approach applies to automotive housings, manifolds and castings: sealing design that does not damage parts, fast clamping, and test pressure and hold times that meet your specification.

Sizing clamps and actuators

Clamping and test cylinders are sized for force with a proper load ratio so clamping stays reliable when air pressure fluctuates. Check your own clamp cylinders with our free pneumatic cylinder force calculator and fixture bolts with the bolt torque calculator.