(608) 346-2392 info@innalytical.com

Product Development

Innalytical Solutions supports small businesses that lack the staff or experience to conduct product development projects.

Please review our collection of sample projects below.

Client Comments

I had the pleasure of working with Paul for many years at Gilman. He always impressed me with his knowledge, creativity and dedication to his work. Paul is one of the most detail oriented individuals I know. His ability to work through problems and think outside the box is a real asset. I would highly recommend Paul to anyone seeking a true professional in engineering.

Michael Greene

Gilman Engineering & Manufacturing

Paul was one of the most innovative, creative and motivated engineers I have ever worked with. His willingness to explore new ideas and technologies to infuse them into practical use was inspiring.

Mike Whitney

Owner, Automation Associates of Watertown, Inc.

Sample Product Development Projects

Klover MiK 26

Parabolic Microphone

The challenge was to create a better long-range microphone for sport television.

The solution was a totally new design based on very old technology.  The input of the audio engineer was used to create a product that address their concerns as well as safety concerns.  The design led to the creation of an entirely new business which is now believed to be the largest manufacturer of parabolic microphones in the world.

Modular Lift Table

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.

Programmable Part Handler

Programmable Part Handler

The challenge was to create a programmable pick & place device which could load and unload parts from automated assembly machines within a X-Z plane. The device needed to be less expensive than commercial robots and have a payload of at least 15 pounds. The standard approach to this type of device a combination of two linear axes mounted perpendicular to each other. The problem with this solution is that the horizontal axis must be considerably larger due the fact that it must carry the extra mass of the vertical axis.

The solution was to place the two carriages in parallel on a linear servo motor stage. The two axis are connected by a linkage that provides a horizontal motion when the two axis when the two axes operate in the same direction and a vertical motion when the two axes operate in opposite directions. With this configuration each axis carries only one half of the payload mass plus the weight of two links.

Smart Conveyor

Modular Conveyor Corner

The challenge, presented by a large automobile engine plant, was to create a heavy duty conveyor that could be operated even if electrical power and the source of compressed air was lost. The modular conveyor described in “Modular Conveyor System” already satisfied this requirement but a new design was required for corners and fixture rotate stations.

The solution was to place four rollers, mounted at 45 degree angles to the normal conveyor path, at the same elevation as the straight conveyor rollers. By rotating the rollers in a direction that was at a 45 degree angle to the required path the applied forces offset each other and the fixture traveled in the desired direction.

Smart Conveyor

Modular Conveyor System

The challenge was to create a heavy duty roller conveyor that did not require the ongoing maintenance and adjustment of friction rollers or clutches normally encountered. An additional challenge was reduce the ongoing maintenance or pallet stops that take a continuous beating as 700 – 1000 pound pallet slammed into them.

The solution was to eliminate the clutch altogether! By using a unique electric motor to drive just one or two rollers an “electric clutch” was provided that eliminated all mechanical clutches. By adding a series of sensors and the required controls the conveyor was able to stop the pallet by reversing the electric motors – eliminating the mechanical stops altogether. This conveyor was extremely reliable as nearly all wear items were removed.

Sample Product Development Projects

Klover MiK 26

Parabolic Microphone

The challenge was to create a better long-range microphone for sport television.

The solution was a totally new design based on very old technology.  The input of the audio engineer was used to create a product that address their concerns as well as safety concerns.  The design led to the creation of an entirely new business which is now believed to be the largest manufacturer of parabolic microphones in the world.

Modular Lift Table

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.

Programmable Part Handler

Programmable Part Handler

The challenge was to create a programmable pick & place device which could load and unload parts from automated assembly machines within a X-Z plane. The device needed to be less expensive than commercial robots and have a payload of at least 15 pounds. The standard approach to this type of device a combination of two linear axes mounted perpendicular to each other. The problem with this solution is that the horizontal axis must be considerably larger due the fact that it must carry the extra mass of the vertical axis.

The solution was to place the two carriages in parallel on a linear servo motor stage. The two axis are connected by a linkage that provides a horizontal motion when the two axis when the two axes operate in the same direction and a vertical motion when the two axes operate in opposite directions. With this configuration each axis carries only one half of the payload mass plus the weight of two links.

Smart Conveyor

Modular Conveyor Corner

The challenge, presented by a large automobile engine plant, was to create a heavy duty conveyor that could be operated even if electrical power and the source of compressed air was lost. The modular conveyor described in “Modular Conveyor System” already satisfied this requirement but a new design was required for corners and fixture rotate stations.

The solution was to place four rollers, mounted at 45 degree angles to the normal conveyor path, at the same elevation as the straight conveyor rollers. By rotating the rollers in a direction that was at a 45 degree angle to the required path the applied forces offset each other and the fixture traveled in the desired direction.

Smart Conveyor

Modular Conveyor System

The challenge was to create a heavy duty roller conveyor that did not require the ongoing maintenance and adjustment of friction rollers or clutches normally encountered. An additional challenge was reduce the ongoing maintenance or pallet stops that take a continuous beating as 700 – 1000 pound pallet slammed into them.

The solution was to eliminate the clutch altogether! By using a unique electric motor to drive just one or two rollers an “electric clutch” was provided that eliminated all mechanical clutches. By adding a series of sensors and the required controls the conveyor was able to stop the pallet by reversing the electric motors – eliminating the mechanical stops altogether. This conveyor was extremely reliable as nearly all wear items were removed.