Final Design
 
After designing a number of designs and going through a complex analysis process of the designs we are down to one design. This design is simpler than the current method used for staking which presents a number of benefits. Because of the simplification, the maintenance and inspection associated with it are lower. The design we chose utilizes a single pneumatic cylinder positioned inside of the chuck. The cylinder is mounted to a base plate that is attached to the bottom of the chuck. The picture above on the left shows the V-Block protruding from the bottom of the face plate. The picture on the right shows the top of the face plate with the cylinder mounted to it.
 
The pictures above shows the bottom section of the chuck. In the picture on the right shows the old alignment components that were removed to accomondate the roller finger follower. The staking tools are the two large rectangular pieces in the middle with the staking tool tips pointing towards each other. When the chuck is in operation, the part to be staked would be moved into position from the right and guided by the two rails in the middle. The rails ensure the rocker arm is secure and in the correct alignment. The two staking tool tips then contract and press on the axle ends, locking the axle into place.
Do to the production needs of GT, we were unable to test our final design on one of the prodcution lines. Instead we did our final testing on an offline set up. GT preferred this method because it allowed for their production lines to continue and it garunteed all problems would be solved before the design would be implemented onto an online assembly line.
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