Automated Heat Exchanger Assembly Machine
Project Overview
This project involved the design and development of an automated machine for assembling heat exchanger cores with varying tube lengths (600 mm, 800 mm, and 1000 mm). The system was designed to meet strict manufacturing, safety, environmental and cost constraints, while ensuring efficient, reliable and scalable production. Emphasis was placed on automation, precision control and design for manufacture and assembly (DFMA).
Tools & Technologies
- 3D CAD Modelling
- DFMA Principles
- Automation & Control Systems
- UML Modelling
- Design Calculations
- Manufacturing Design
Project Details
Designed a fully automated machine capable of assembling heat exchanger cores with multiple tube lengths (600 mm, 800 mm, and 1000 mm) within a compact 4m³ working envelope.
Integrated an expansion gun system and automated tube insertion mechanism to assemble 85 tubes into dual tube sheets with high positional accuracy.
Applied DFMA principles to minimise bespoke components (<20%) and improve manufacturability, cost efficiency, and ease of maintenance.
Developed system architecture using UML and implemented closed-loop control with encoders to ensure precision, repeatability, and process stability.
Designed for safe and efficient operation, including automated workflows, accessible loading zones, emergency stops, and compliance with ISO and EU safety standards.
Key Results
- Automated assembly of 85 tubes per heat exchanger core
- Cycle time overachieved by 33%, completing each heat exchanger in 40 minutes (target 60 minutes)
- Delivered the project 8% under budget at £69,022 (target £75,000)
- System footprint: 3.7 m × 2.0 m × 3.3 m, designed for a 10-year lifespan with 8-hour daily operation
- Compliant with ISO 9001, ISO 14001, and ISO 45001 standards
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