The challenge was to extend the life of a 35+ year old machine tool.  The control hardware was no longer supported and failures were becoming more common.  After servicing the machine for more than four years it was finally impossible to find replacement components.

It was agreed that the long-term solution was to replace both the controller and servo drives of the large boring bar. 

The challenge was to trim the bristles of a molded brush head that came in a range of sizes and shapes.

The solution was a simple cell adjustable motions that allowed the brush diameter to be set anywhere within a defined range.  The corner radius could also be adjusted within a wide range.

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.

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.

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.

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.

The challenge was to design a scissors lift table that could be readily converted from hydraulic to pneumatic power or changed between three different lifting capacities.

The solution was a modular design with bolted joints. Five basic frame sizes are utilized to build the seven standard configuration. These standard frames are then mated to one of fifteen standard table tops or optional modules such as a tilt table.

The challenge was to design a  mechanism to drive an internal adjustment (regulation) using an external electric motor, while also providing feedback from the adjustment mechanism, or by using a hand tool.

The solution was a unique combination of drive components which is proprietary to our customer.

In addition to the mechanical design, we also conducted Finite Element Analysis of various components.

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.

The challenge was to test a wide variety of hydraulic valve packs in a single test stand.

The solution was test stand with modular fixtures that adapted the different valve packs to the test stand.