We have a very broad and deep background in manufacturing and automated machinery. The majority of our clients are OEMs where automated machinery is a given. We have partnered with several clients for application specific machines and we have developed (solo) multiple automated machines. Some of our projects are:
This machine punches various diameter paper and mylar washers (shims) for musical instruments. The process automatically feeds, punches, collects and batches these washers or “shims”. The machine is totally automatic and will signal the operator upon completion of a batch or machine fault. The number of shims per batch as well as the number of batches can be programmed via a touchscreen. All functions are done with a PLC of the client’s choice. ADC was responsible for the mechanical/electrical design, software development and construction of this machine. We have made multiple upgrades (at the customer’s request) on this machine that include, faster PLC, anti-static and de-ionization of the material mylar material. This was a very, very successful project.
Linear Coating Machine
This device draws wire from an emulsion tank at a given rate for precision thickness coating. This machine is totally automatic. The operator enters the length of the device to be coated and the machine takes it from there. Velocity and other parameters are also adjustable by the customer. ADC was responsible for the mechanical/electrical and software development of this machine.
Grommet Insertion Machine
The machine was designed in collaboration with Champion Laboratories who produces oil filters for Jaguar, Harley etc. This machine would line up 20 filters into a que for a 2-step insertion process. Once queued, a high torgue servo system would fit or “press” the grommets into the end of the filters. The fitted grommets would then travel to the 2nd step where they would be flipped and the process would be repeated. After the 2nd step, the filter assembly would be sent for insertion into the can then inspection and packaging.
This machine was developed in partnership with a textile company. This machine would take the waste material from the carding and cleaning process and form it into a high BTU “puck” that can be burned. The idea of the material feed and the control of the material feed was our invention. Additionally, automatic feed compensation (volume) was also our invention. This machine was hydraulically controlled due to the high pressures required. Today this can be achieved with servo motors. We were awarded 2 patents for this machine.
PROCESS & MACHINE AUTOMATION
Our years of manufacturing experience ties in with automating various manufacturing processes. For example, we can take what is a manual process such as applying a bead of glue to a lid, and then automating that process for faster thru-put, less waste, possible lower energy costs and higher efficiency. We can take existing semi or fully automated machinery and upgrade/convert them to state of the art controls with operator interfaces, alarm and alarm management, parts count and data collection for manufacturing data collection.
Process Automation can include fully automating manual multistep functions into a 1 button fully automated process function. Most of these applications can be done with PLC or PAC controllers with touch screens for operator interface, alarm management and equipment diagnostics.
One of the areas we enjoy is the application of instrumentation for various applications. Our most recent project was a measurement machine that would measure and record the thickness of brake pads after the completion of a grinding process. The laser had the capability of measuring down to a few microns. When the material passes under the laser we would sample (take 10 reading) that represent the thickness of the brake pad. In so doing would calculate/extract various data points that include pad thickness, parallelism, deviance from standard etc. We have a depth of knowledge with Temperature, pressure and flow instruments. High temp measurement applications, ultra-precise linear measurement applications (several microns), Encoders, positioners and resolvers. LVDTs for linear measurement, PID loop control and a host of many other types of instrumentation and applications.
I personally have over 20 years in incineration technology. This includes Controlled Air Modular Incinerators, Baghouses, Boilers, Emissions Control Equipment, Stacks, ID Fans, Ash Removal Systems, Burners, Blowers, Stochiometric and sub-stochiometric burring applications. We are certified to teach and certify incinerator operators in NC, SC and GA. All phases of the incineration process as well as repair, upgrades, retrofits and training are all part of our portfolio as well as annual or bi-annual inspections as required by local, state or federal regulators. We are probably the most experienced team with incineration technology in this region and possibly the country. That is a broad statement, but we can back-it up with our level and years of experience and expertise.
Because of our manufacturing background, we have been asked to develop some simple assembly machines. These have included simple pick and placement devices using pneumatics, hydraulics or servos. Position and alignment machines/devices, insertion or extraction machines/devices etc.
HYDRAULIC, PNEUMATIC & VACUUM SYSTEMS
In developing custom machinery, we apply pneumatics or hydraulics for various functions. We hold 2 patents for development of Hydraulic Controls and Hydraulic Control System(s), Patent #5,326,511 & Patent #5,582,846. Many of our applications include some type of vacuum generation for pick & place, stripping etc.
AC/DC & SERVO SYSTEMS
We have a wealth of experience in all types of AC drive and DC drive systems, WEB control, tension control, etc. Many of our custom machines and automation upgrades includes a DC or AC drive, servos, steppers etc. We have worked with DC drive systems from fractional horsepower to a multidrive system that utilized 2 1000HP drives. One our applications was a wire draw machine that utilized
6 800 HP DC machines operating in series configuration. We have upgraded multi drive printing presses, Parts coating machines, narrow slitting machines, wire draw machines, high speed assembly machines, presses etc.
Various applications have included parts placement, cutting and punching applications, Drawing and coating applications. Rotary or linear adhesive applications, stripping applications using servos & steppers.
SAFETY & MACHINE INTERLOCKING
We have built and developed various safety systems for various clients that include, safety matts, light curtains, mechanical guarding, two handed press controls, operator in area presence detection, safety cages etc.
HMI, DATA ACQUISITION & SCADA CONTROL
Data collection has become ubiquitous in the manufacturing environment along with intelligent machine control. We work with various software packages such as Wonderware, Indusoft, CIMPLICITY, RS View, PROFICY and many other packages. We support MAPLE, Red Lion, EXOR, Allen Bradley, GE and many other HMI/OIU packages.
PLC & HMI PROGRAM DEVELOPMENT
As with the HMI & SCADA systems we have software and support all Allen Bradley, All GE Including 90/30, 90/70 Series 1 and series 5 processors, All Automation Direct, Siemens, Omron, Mitsubishi, Velocio, Unitronics, and others. We also teach PLC program development for Allen Bradley, Control Logix & SLC platforms & Automation Direct. As with the HMI & Data acquisition program development, we support all Maple, All Red Lion, Exor and a host of others.