Machine Design – Automated Battery Module Assembly Machine image

Machine Design – Automated Battery Module Assembly Machine

Project Overview

This project formed part of the Design, Materials, and Manufacturing module and involved designing a fully automated machine to assemble battery modules for use in electric hovercrafts.

Skills Used

CAD Stress and Strain Analysis Fatigue and Failure Analysis Product Selection Sketching DFM UML Activity Diagrams DFMEA FTA (Fault Tree Analysis)

🛠️ Project Overview

As part of the Design, Materials, and Manufacturing module, I worked in a team to develop a concept for a fully automated machine that assembles battery modules for an electric hovercraft. The challenge: design a system that could handle every step — from sorting cells to spot-welding connections — under a strict time and budget constraint.

🎯 Objectives

The machine had to perform the following tasks:

  1. Unpack cylindrical battery cells
  2. Sort them by polarity
  3. Place them into carriers
  4. Spot-weld copper strips for electrical connectivity
  5. Eject completed modules
  6. Complete a full cycle in under 200 seconds
  7. Stay within a budget of £20,000

📄 Click here to view the full brief (PDF)

📦 My Contributions & Deliverables

Throughout the project, I contributed to the design and evaluation of the system by producing:

✅ 3D CAD models of the full assembly and critical sub-systems
✅ UML activity diagrams to visualise system logic and task sequencing
✅ Manufacturing operations plan outlining each production stage
✅ DFMEA and fault tree analysis to identify risks and failure modes
✅ Storyboard and physical layout showing process flow and ergonomics

📘 View the Full Report

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📐 View the Technical Drawings

💬 Final Thoughts

This project tested my ability to balance creativity with feasibility in a fast-paced, multidisciplinary team. From selecting components to evaluating system logic and risk, I gained hands-on experience in applying design-for-manufacture (DFM) principles, safety assessments, and collaborative problem-solving. The tight timeframe pushed my CAD and time management skills — and gave me a real taste of system-level mechanical design in a professional setting.