Question: help PROBLEM 2 [ 2 0 MARKS ] Volkswagen Group Malaysia's assembly facility in Pekan, Pahang, Malaysia, has been tasked with designing critical static service

help PROBLEM 2[20 MARKS]
Volkswagen Group Malaysia's assembly facility in Pekan, Pahang, Malaysia, has been tasked with designing critical static service helical compression springs for their RM10.5 million modernization project of the Volkswagen Tiguan assembly line. These springs, essential for the robotic handling system in the advanced chassis assembly station, must comply with Volkswagen's global process requirements and Malaysia's MS ISO/TS 16949 automotive standards while supporting sustainable manufacturing under Malaysia's National Automotive Policy 2020. The springs must reliably support a 100 N load through a 50 mm compression stroke, managing approximately 240,000 cycles annually across two-shift operations in Pekan's tropical climate conditions (average temperature \(35^{\circ}\mathrm{C},85\%\) humidity). Design specifications mandate a static safety factor \(\left(n_{s}\right)\geq 1.2\), solid height \(\leq 50\mathrm{~mm}\), free length \(\leq 125\mathrm{~mm}\), and a fractional overrun to the closure \((\xi)\) of 0.15 for consistent linear response. Following the PROTON-VW localization initiative and PEKAN Engineering lean inventory management system, wire diameters must be selected from the DRB-HICOM-TECK SEE approved inventory stock (available diameters: \(1.9,2.1,2.3,2.4\), and 2.6 mm ). The springs must accommodate Volkswagen's standardized operation in a 25 mm hole mounting system, which requires a 1.1 mm diameter clearance allowance to prevent interference during high-speed operation and compression cycles. The final design must satisfy Volkswagen's global quality standards while ensuring compatibility with Pekan's tropical-grade assembly protocols and maintaining Malaysia's automotive ecosystem.
help PROBLEM 2 [ 2 0 MARKS ] Volkswagen Group

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