CASE STUDIES
We've pioneered our company to focus on engineering solutions
Cable slitter
issue:
A Cable manufacturer needed a way to slit the clear insulator without nicking the wire so it can be routed to several places in the customers electronic enclosure.
Solution:
The cable is fitted snugly into a machined slot. The sharp blade is slid manually to the start of the slit. The carriage is adjusted laterally with a knob to place the blade between the wires. The operator pushes down at the start of the slit. The operator slides the carriage to the end of the cable.
Result:
No defects nicking the conductor
tip conveyor
issue:
A large manufacturer with a robot station needed a conveyor system for automated feeding of baskets with several parts parts in it.
Solution:
A tipping conveyor system was developed that utilizes input and output storage stations with stops that can be released when needed by robot commands, keeping manual intervention to a minimum.
Result:
The prototype has 2 basket input stations with basket stops. The pneumatically actuated tipping station accepts full baskets for robotic pick and place. When the basket is empty, the tip conveyor lowers and it is moved into the empty storage.
connector press
issue:
A 2 ton press was needed to force a compliant pin connector into a large circuit board.
Solution:
We designed a large Steel C Frame press that could safely generate 3 tons of force while pushing the compliant pin connector into the large customer circuit board.
Result:
This prototype manufacturing tool performed hundreds of connector insertions to help the contract manufactured meet deliveries
Cutlerease
issue:
Utensil delivery systems are dirty, take up too much space.
Solution:
Automatic utensil delivery system. Offer bio-degradable utensils to your customers.
Result:
Product launch!
dip insertion head
issue:
A large manufacturer of electrical insertion equipment developed several Dual Inline Package (DIP) heads that were expensive, difficult to manufacture and were very unreliable.
Solution:
We engineered a new machine and made a prototype that was adopted by all levels of management.
Result:
The new head is half the cost to produce, faster, and three times more reliable than the previous heads. Our machine became the industry standard worldwide.
Jumper Head
issue:
An electronic manufacturer had subcontracted other Jumper Heads that were (1) Pneumatically actuated (noisy), (2) Required a great deal of time to setup and keep running, (3) Consuming time for tool changes, and (4) had a separate wire feeder.
Solution:
We developed a new Jumper Head that was all mechanically driven by one motor including the wire feeder.
Result:
The new Jumper Head is quiet and tooling changes take only 5 minutes. The head is capable of running at 4 jumpers per second. Approximately $1M recouped cost.
Circuit Board drilling machine
issue:
A major computer manufacturer needed a high-speed drilling solution for large panel circuit board manufacturing.
Solution:
We developed the fastest circuit board drilling machine in the world capable of drilling 2500 holes per second. The machine needed a 400 HP air compressor to run 180 spindles capable of 130,000 RPM.
Result:
the machine saved the company $25 billion etc
36MM Auto Impact Pinner
issue:
A large computer manufacturer needed a way to attach 300 copper pins to a chip carrier ceramic substrate.
Solution:
The pins were fed and located into a ceramic substrate , cold impact formed with a head and bulge on both sides of a ceramic substrate to hold them firmly in place.
Result:
Several machines were built, and the new machines saved the company 5 billion dollars of labor and value add over their lifetime…
Automatic Chip Remove and Dress Machine
issue:
A large computer manufacturer needed a way to remove misregistered or electrically bad chips from multi chip modules to save reflow cycles and dress the solder for the site so another chip could be placed there.
Solution:
All work is done in a nitrogen environment. Modules are loaded and moved thru a pass thru then 3 pre heat stations. The chip is heated with focused IR and suction removal. A nickel plated sintered copper billet is placed on that site and heated to remove all residual solder.
Result:
The machine saved the company 2 billion dollars of labor and value add over the life time of that machine.
Contact us today to find a solution
