(608) 346-2392 info@innalytical.com

Automated Assembly

Innalytical Solutions supports businesses that lack the staff or experience to complete assembly automation projects.

Our founder has been involved with dozens of assembly automation projects throughout his career.  We provide expertise in the development of automated assembly systems and assembly processes.

Please review our collection of sample projects below.

Client Comments

Paul’s innovative R&D developments at Gilman provided a competitive advantage for winning new business. His engineering expertise and comprehensive knowledge of automation combined with fresh, creative approaches to problems can benefit any challenge.

Dave Shoemacher

Account Manager, ATS Automation Tooling Systems

very creative… talented in a wide range of fields… reasonable to work with… responsible for one of the most amazing automation systems I’ve ever seen

Simon Melikian

President / CEO, Recognition Robotics, Inc.

Sample Automated Assembly Projects

Insulated Glass Panel

The challenge was to assemble insulated glass panels utilizing a very unique spacer between the glass panels.

The solution included a spacer transport system, a rotary assembly / forming station, as well as a gas fill station.

Main Assembly Cart

Axle Assembly System

The challenge was to assemble a large axle assembly with a totally flexible / reconfigurable system while using only battery powered torque wrenches.

The solution was a series of portable assembly cell along with hand powered transfer carts and assembly fixtures carried by Automated Guided Vehicles (AGVs) .

Robotic Assembly & Packaging Cell

The challenge was to install various components into injection molded parts coming directly from the injection molding machine.

The solution was a robotic cell with interchangeable tooling that allowed 11 different automotive parts to be assembled and packaged for shipment to the assembly plant.

Broaching Dial Redering

Tumbler Broaching Cell

The challenge was to automatically broach the slots in a small lock tumbler.

The solution was dial based cell that could broach and inspect the lock tumbler.

Semi-Automatic Tire Assembly

The challenge was to provide a machine that would disassemble a three piece rim assembly and then assemble the complete pneumatic tire. The tires are used used on off-road equipment excavating equipment and weigh up to 1,500 pounds. The tire design presented many ergonomic and safety issues as the tires range in size from 50” to 65” in diameter and from 12” to 24” in width.

The final machine automatically removed the “lock ring” that keeps the rim parts securely connected but provided an ergonomic method of re-installing the lock ring after the tire had been installed.

Modular Assembly Fixture

Modular Assembly / Test Fixture

The challenge was to design a  modular fixture that would allow multiple products to be assembled and tested within the same assembly cell.

The solution was a series of small modular fixtures based on die stamping components that allowed various parts to be assemble and tested. 

Fuel Tank Leak Test

Fuel Tank Leak Test

The challenge was to design a system to leak test a fuel tank, by dunking the pressurized tank under water, with the ability to easily locate the source of the leak.

The solution was a mechanism that lowered the fuel tank into the dunk and then rotate the tank so all sides were visible under water.

Boom Pin Press

The challenge was to press a large pivot pin into the large boom of an excavator. The solution was a large tool balancer that supported a floating frame, which included a press cylinder, that would pull the pivot into the boom and frame. Innalytical Solutions...

Hydraulic Suspension Component Assembly & Test #2

The challenge was to design a system that could safely assemble and test several different sizes of the suspension components. In addition the machine had to contain the 1,300,000 pounds of force produced during the functional test of the assembly.

The solution was a seven axes, servo operated machine that assembles the various components into the main housing and then rotates the assembly vertical for functional testing. A 12” bore hydraulic cylinder backs up the assembly as it is tested.

In addition to the mechanical design, we also conducted Finite Element Analysis of the structure and programmed all the servo axes.

Hydraulic Suspension Component Assembly & Test #1

The challenge was to design a system that could safely assemble and test suspension components that weigh up to 4 tons each. In addition there were seven different sizes of the completed assembly.

The solution was a ten axes, servo operated machine that assembles the various components into the main housing and then rotates the assembly vertical for functional testing. In addition to the mechanical design, we also programmed all the servo axes.

Sample Automated Assembly Projects

Insulated Glass Panel

The challenge was to assemble insulated glass panels utilizing a very unique spacer between the glass panels.

The solution included a spacer transport system, a rotary assembly / forming station, as well as a gas fill station.

Main Assembly Cart

Axle Assembly System

The challenge was to assemble a large axle assembly with a totally flexible / reconfigurable system while using only battery powered torque wrenches.

The solution was a series of portable assembly cell along with hand powered transfer carts and assembly fixtures carried by Automated Guided Vehicles (AGVs) .

Robotic Assembly & Packaging Cell

The challenge was to install various components into injection molded parts coming directly from the injection molding machine.

The solution was a robotic cell with interchangeable tooling that allowed 11 different automotive parts to be assembled and packaged for shipment to the assembly plant.

Broaching Dial Redering

Tumbler Broaching Cell

The challenge was to automatically broach the slots in a small lock tumbler.

The solution was dial based cell that could broach and inspect the lock tumbler.

Semi-Automatic Tire Assembly

The challenge was to provide a machine that would disassemble a three piece rim assembly and then assemble the complete pneumatic tire. The tires are used used on off-road equipment excavating equipment and weigh up to 1,500 pounds. The tire design presented many ergonomic and safety issues as the tires range in size from 50” to 65” in diameter and from 12” to 24” in width.

The final machine automatically removed the “lock ring” that keeps the rim parts securely connected but provided an ergonomic method of re-installing the lock ring after the tire had been installed.

Modular Assembly Fixture

Modular Assembly / Test Fixture

The challenge was to design a  modular fixture that would allow multiple products to be assembled and tested within the same assembly cell.

The solution was a series of small modular fixtures based on die stamping components that allowed various parts to be assemble and tested. 

Fuel Tank Leak Test

Fuel Tank Leak Test

The challenge was to design a system to leak test a fuel tank, by dunking the pressurized tank under water, with the ability to easily locate the source of the leak.

The solution was a mechanism that lowered the fuel tank into the dunk and then rotate the tank so all sides were visible under water.

Boom Pin Press

The challenge was to press a large pivot pin into the large boom of an excavator. The solution was a large tool balancer that supported a floating frame, which included a press cylinder, that would pull the pivot into the boom and frame. Innalytical Solutions...

Hydraulic Suspension Component Assembly & Test #2

The challenge was to design a system that could safely assemble and test several different sizes of the suspension components. In addition the machine had to contain the 1,300,000 pounds of force produced during the functional test of the assembly.

The solution was a seven axes, servo operated machine that assembles the various components into the main housing and then rotates the assembly vertical for functional testing. A 12” bore hydraulic cylinder backs up the assembly as it is tested.

In addition to the mechanical design, we also conducted Finite Element Analysis of the structure and programmed all the servo axes.

Hydraulic Suspension Component Assembly & Test #1

The challenge was to design a system that could safely assemble and test suspension components that weigh up to 4 tons each. In addition there were seven different sizes of the completed assembly.

The solution was a ten axes, servo operated machine that assembles the various components into the main housing and then rotates the assembly vertical for functional testing. In addition to the mechanical design, we also programmed all the servo axes.