Faculty Advisor

Norton, Robert L.


The sponsor has a manufacturing process that requires the insertion of a product into a housing slot. This stage of the assembly has been a source of scrap; however, the primary cause is undetermined. This project outlines the design of a testing fixture to simulate the product insertion process and analyze the effects of misalignment on the success of assembly attempts. A linear servo is used to simulate the tooling approach path. A micrometer-driven XY stage is used to induce an adjustable offset between the housing and tooling in the plane perpendicular to the tooling approach. Sensors are used to align the product and housing slot and to measure the geometric characteristics of the product. The nest and tooling are mounted on modular plates to allow various product lines to be tested.


Worcester Polytechnic Institute

Date Accepted

April 2012


Mechanical Engineering

Project Type

Major Qualifying Project



Advisor Department

Mechanical Engineering

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