Projects

Assembly Machine Control Update

Old control cabinet for an assembly machine needed updating.  With the new updated components and much cleaner wiring, we were able to control the steps of the process and ensure they were done to quality standards.  Before, the machine would just stop and the operator had to guess where it had gotten stuck.  We added indicators to which step in the process the operator was on.  A strain gauge torque wrench was added to the machine to ensure bolt torque was acheived in the assembly process.  The new control included wi-fi, datalogging, and built to UL508 standards.

New Control Cabinet
New Control Cabinet

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Old Wiring
Old Wiring

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Old Enclosure
Old Enclosure

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New Control Cabinet
New Control Cabinet

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Air Compressor Monitoring System

A customer wanted the ability to monitor the air cfm and motors loads of their three 150hp air compressors. This was accomplished by utilizing Adam modules, Advantech industrial monitor, and an Intel compute stick.  4-20ma load sensors were placed on each air compressor and fed back to the control cabinet.

Control Cabinet
Control Cabinet

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Industrial Monitor
Industrial Monitor

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Industrial Monitor
Industrial Monitor

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Control Cabinet
Control Cabinet

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Fixture Air Gap Sensors

A Customer needed air part seat sensors added to a fixture on a CNC mill.  These sensors were wired into the machine's Fanuc control and programmed for alarms during cycle and after the fixture clamping cycle.

Ball Press Control Cabinet

A press assembly machine was controlled by pneumatic two hand controls.  This resulted in many failed quality parts produced on the machine.  The goal was not only to improve the process but monitor and log each cycle of the machine's data to ensure a quality part was produced.  A Micro 820 was used for the PLC control, Banner run bar with a two hand control module, and wifi were utilized for acquiring data for cycles.

Enclosure
Enclosure

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Control Cabinet Subplate
Control Cabinet Subplate

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Control Cabinet
Control Cabinet

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Enclosure
Enclosure

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Lathe Autodoor

A customer wanted an autodoor on a lathe for a robot cell but wanted a different option other than an air cylinder.  Utilizing an Oriental Motor stepper motor/drive combo and an IGUS linear actuator we were able to give the customer the option to change to speed of the door.  With the stepper motor option on the machine, the customer has the ability to signal the robot immediately once it is in a safe position for the robot to enter.  The stepper control logic was tied-in and programmed directly into the machine tool's Fanuc control.

Hydraulic Press Rewire

A simple hydraulic press was purchased and had some hard to navigate wiring.  This was just a rewire and draw schematics for ease of future troubleshooting.  In the process we were able to inform the customer how to press operated.

Before
Before

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Before
Before

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After
After

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Before
Before

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Check Stand

This control cabinet was built and programmed to check assemblied parts.  A Micro 820 PLC and a EA9 Cmore HMI was used for this project.  An Adam ADC module was added to monitor position cylinders that were used for checking the part dimensions.  The customer is able to select between different size parts and edit parameters seperately between each.  

Enclosure
Enclosure

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Control Cabinet
Control Cabinet

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Control Cabinet
Control Cabinet

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Enclosure
Enclosure

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Cincinnati OBS 75 Retrofit

One of our customers had a Cincinnati OBS 75 hydraulic press that the control had died on it.  Instead of going with the costly OEM retrofit solution, we were able to retrofit the machine with a much more cost effective solution.

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Jones and Lamson Thread Grinder Rebuild

One of our customers had an old Jones and Lamson Thread Grinder.  After countless service calls to band-aid the problems on this machine, we finally ran out of band-aids.  The old control circuit was 200vdc and when the contactors started to fail the best course of action was to replace the control panel with updated components.

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Excello Thread Grinder Servo Retrofit

One of our customers had purchased a used Excello thread grinder.  The hydraulic motor that ran the machine was leaking constantly.  The machine would not operate properly and was difficult to set up job to job.  We proposed the solution of retrofitting the machine with a servo motor and linear scale for positioning to replace the existing methods of operation.

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Williams White 1500-144-108

A new customer had a massive 1500 ton hydraulic press that had been sitting inoperable fomr 2 years.  The control was outdated, unsupported and unrepairable.   I was called in the try and retrofit the system with something more modern.  The end result was a PLC and HMI interface to take place of comparator cards and a wall of potentiometers.