Case Study: Automotive Damper Drive Shaft Assembly Lift Assist

Application: At this automotive assembly facility, operators picked up the combined damper and drive shaft assembly — close to 80 pounds when assembled — and installed it onto vehicles slowly moving down the assembly line. The cycle ran every 20 seconds.

Problem: Customer had a model change which meant the existing tool would no longer work once parts shipped in from overseas. Since the drawings did not match the sample parts, engineering needed four new tools in under a month.

Solution: With a high-cycle application, simplicity and reliability in the grip mechanism were the priority. We designed a mechanical lift assist that trapped the part around a center tab, with a secondary mechanical clamp around the damper for stability. The clamp-and-trap device was manufactured from UHMW (ultra-high-molecular-weight polyethylene) to prevent product damage on contact. The lift assist was integrated with a Zimmerman air balancer, allowing the operator to feather the device smoothly at pickup and set-down.

Result: Ergonomic Partners delivered all four lift assist tools within the month. SolidWorks drawings were submitted for customer approval before fabrication, giving engineering a clear picture of how each tool would operate. The combination of a high-speed air balancer and a simple mechanical grip was the right match for this high-cycle application.

If your facility has a similar application — heavy assemblies, tight cycle times, or a short delivery window — Ergonomic Partners can help. Contact us to discuss your lift assist requirements. We serve clients from coast to coast, Canada, and Mexico, and are especially focused in the states of Missouri, Illinois, Indiana, Iowa, Kansas, Nebraska, Arkansas, Mississippi, Tennessee, Kentucky, South Carolina, Florida, and Oklahoma.