Rotary Indexing Table Design for Tailgate and Glass Handling

The client initially approached us to design a flipping station with a fixture to handle a specific glass–tailgate assembly.

But during early discussions, we learned they planned to handle more part variants in the future. So instead of designing a single-use fixture setup, we proposed a 3-axis rotary indexing table that could accommodate up to three fixtures, giving the client more flexibility with minimal future investment.

Our team studied load constraints, model variants and layout feasibility to create an optimized solution. This proactive approach helped the client:

• Avoid repeated investments in future setups
• Speed up cycle time and reduce changeovers
• Plan for long-term growth without rework

Leveraging our expertise in industrial automation solutions, our design team created a 3D model that met all requirements and design standards.

Here’s how we approached the design and developed a solution that met both current needs and future goals:

1. Fixture Designed for Safe and Precise Handling

We started by designing a custom fixture tailored to the current glass–tailgate combination. Our main focus was protecting the glass during flipping while ensuring accurate alignment and support.

Key design features:

• Nylon rest pads were added at all glass contact points to prevent scratches, cracks, or pressure marks.
• Ten vacuum cups were strategically positioned to evenly distribute the tailgate’s weight.
• Two clamping units were included at the bottom to ensure the part remained secure during flipping.
• Guiding blocks across the fixture width helped operators easily align the tailgate before loading.

This setup ensured reliable part handling without damaging the fragile glass, even during flipping.

2. Rotary Indexing Table Designed for Flexibility

To accommodate future model variations, we designed a 3-axis rotary indexing table capable of holding three fixtures at once. These were arranged in a triangular layout, allowing each fixture to rotate independently without interference.

Design highlights:

• The table was designed to carry up to 900 kg, including fixtures and parts, with a proper factor of safety.
• A servo motor was integrated to enable precise and smooth rotation to support automated assembly.
• For the current setup, we designed one fixture to hold the glass–tailgate combo, while the other two stations were fitted with counterweights to maintain balance.

In future scenarios, these counterweights can be replaced with two additional fixtures to handle different models, increasing productivity without redesigning the base structure.

3. Presence Detection and Docking Interface

To verify correct part placement before rotation, the system included 4 distance sensors to detect the presence of both the tailgate and the glass. This ensured safe operation and prevented accidental motion without parts.

The fixture also included a locating and docking assembly for proper alignment with the robot’s End-of-Arm Tooling (EOAT). This enabled precise pick and place operations.

4. Compact, Line-Friendly and Serviceable

We kept the entire system compact enough to integrate into existing automotive assembly lines. Our modular fixture design allowed quick changeover and easy maintenance, while the use of standard components and open access points ensured serviceability with minimal downtime.

Our team ensured the equipment is simple and user-friendly. It can be conveniently combined with any application and fixtures can be upgraded for future requirements.

5. Design for Manufacturability and Compliance

All the safety and ergo standards were met as per the end client’s standard. We designed and modeled the rotary indexing table along with fixture while taking all the DFMEA (Design Failure Modes and Effects Analysis) into consideration.

With the help of Sedin’s cost effective and state-of-the-art idea, the entire machine was able to work continuously without any hassles and thereby increasing productivity.