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Machining Systems
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Consumer Goods Industry - Case Study #4297
Application -
Develop a high-speed secondary operations system to tap a metal plate in multiple locations.
Challenge -
Design and manufacture a custom machine to tap three holes in a metal plate at a rate of 40 parts per minute while accommodating a family of over one dozen part configurations and sizes.
Solution -
Design and build a custom twelve station machining system with a bank of 6 quick changeover Sugino tapping heads. The operator loads parts in a two-up pallet at station number one and two. The third through eighth stations consist of Sugino tapping heads, which are mounted to quick-change stanchions. All taps are monitored for premature failure. The quick-change fixtures and stanchions are color coded to allow for changeover to a new part in less than 10 minutes. The finished parts are then cleaned off with and air knife and ejected off onto a chute for use.
Bottom Line -
The machine increased the customer’s production 100% over their previous method allowing them to realize significant gains while improving quality and reducing scrap .
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Electronics Industry - Case Study #4121
Application -
Develop a semi-automatic secondary operations method to increase output of an armature body.
Challenge -
Machine needs to be designed in an ergonomically friendly means to accommodate an operator tending to two operations .
Solution -
Design and build a custom eight station machining system. The first station consists of an operator load station where the operator loads the armature blanks into the pallet and initiates cycle start. The second station consists of an inspection station that monitors proper part placement. The third station consists of a dual drill station, which processes two holes into the armature. The fourth and fifth stations tap the target holes to the proper size. All taps and drills are monitored for tool breakage. The six station consists of a Dorner offload conveyor and Festo pick and place unit .
Bottom Line -
The machine dramatically increased the customer’s output and decreased the amount of quality issues with the product . |
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Automotive Industry - Case Study #2586
Application -
Assemble a magnet deep into a Sensor Body automatically.
Challenge -
Magnets are susceptible to chipping and damage due to mishandling during assembly operations.
Solution -
Design and build a semi-automatic Two-Piece assembly system utilizing automatic feeding of the Magnet. An Operator places the Sensor Body onto a post, optics verify the Sensor Body is in position and ready for assembly. The part is clamped and a Ram inserts a Magnet in between two supports located at the bottom of the body. Sensors verify the proper depth of the Magnet prior to releasing part to operator.
Bottom Line -
Due to the Automatic Dispensing and placement of the Magnet, mishandling and or chipping of the Magnet are minimized and scrap was reduced significantly.
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