Case Study: Semi-Automatic Weld Fixture

Background:  A worldwide crane manufacturer recently called upon Specialty Design to design and build a weld fixture for a crane boom that would both decrease manufacturing time and create a safer environment for their workers.  We were up to the task, and we were fortunate to draw upon 40+ years in the business of building custom fixtures.

                

Solution:  Specialty Design worked with the customer to design and build a series of expanding mandrel-type fixtures that incorporated the following features:

• Lengths up to 45 feet
• Reinforced structural construction
• Grounding rail on both sides
• Exact expanded dimension
• Hydraulic cylinders with valves
• Guide rods / adjustable feet
• Lifting lugs

These new mandrels greatly reduced what was once a very time-intensive and dangerous labor process in the production of a crane boom.

                   

         

Case Study: Dual Filling Machine for Dentistry Supplier

Background:  A dental supply manufacturer needed a complete system that would feed, orient, and spray print a compule, at approximately 1" long and a 1/4" diameter.  To fulfill their objectives and satisfy their budget requirements, the customer desired a fully automated system, which would work at a rate of 120 pieces per minute.

              

Solution:  We designed and built a system to perform the customer-requested functions with the following features:

• Tooled vibratory feed bowl
• Vibratory feed track
• Eight-station Cam-type index unit with eight pocket-type Cam-driven fixtures
• Commercial printer
• Dual-track escapement chute with flip-arm for batching
• Heat-seal bagger with Interloc

The customer can now batch feed a machine that will print at 120 pieces per minute, count, and bag parts to programmed batch sizes.  Printing includes product, date of manufacture, and the manufacturer's name.

             

                     

                

Case Study: Press Conveyance System

Background:  A pharmaceutical equipment manufacturer needed a special machine to eliminate the labor-intensive operation of removing molded plastic handles from their tree.

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Specialty Design was able to offer a cost-effective solution...

 

Solution:  We designed and built a press that cut the handles from the tree at a rate of 32 pieces per cycle at a 12 second cycle time.  The unit utilized the following features:

• Commercial base frame
• Pneumatic press
• Custom die
• Chain feed with WHMW nests
• On-demand feed cycle

 

Case Study: American Red Cross Coagulant Dispensing Machine

Background:  For numerous applications, medical practitioners such as those at the Red Cross utilize absorbent pads for applying coagulants.  For example, in order to decontaminate operating room surfaces or clean blood off of patients, these pads are impregnated with coagulants and are kept sterile, lint-free, soft, and slightly abrasive. 

Prior to approaching Specialty Design, the Red Cross dispensed coagulants onto absorbent pads by hand.  This approach proved to be too slow and the application too inconsistent.  Specialty Design was able to offer a cost-effective solution...

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Solution:  We designed and built a special machine that had the following features:

• Robotic gun movement
• Pneumatic dispensing guns
• UHMW bottle tray
• Stainless/UHMW gauze tray
• PLC control
• Alumninum/Lexan guarding

The Red Cross can now produce coagulant pads in one table load at 30 second cycle times.  Furthermore, coagulants are dispensed in a more uniform and consistent fashion.  Not only did our special machine meet the Red Cross' firm expectations for producing a critical product, but the Red Cross informed Specialty Design that the machine has most recently been provided for military use.

Case Study: Precision Filling Line

Background: 

A pharmaceutical company required a bottle fill machine for a new type of resin, as none of the commercially available machines would satisfy their needs. 

See Specialty Design's solution below...

Solution: 

Specialty Design designed and built a machine that satisfied customer's requirements to fill long-neck bottles at a rate of 300 per minute with a precision fill.  To work with the new type of resin, the machine utilized the following features:

• A stainless steel framework
• A vinyl slat conveyor
• A screw driven resin feed hopper
• A vibratory system for resin chute and bottles

Case Study: Molding Press for Submarine Batteries

Background:

Battery manufacturer required a press to make large (40 in. x 90 in.) battery grids. 

See Specialty Design's solution below...

Solution:

Specialty Design designed and built a large horizontal press that integrated the following features:

• Hydraulically powered, floating, ram-on guide rods and bushings
• Heated platens
• Overhead crane to load and unload the molds

Case Study: Moving Gantry for Automotive Gluing and Forming Application

Background: 

Fortune 500 customer wanted to automate their production of formed carpet for the automotive market. Their existing production method was inefficient, too labor intensive, quality was not consistent and volume was inadequate.

See Specialty Design's solution below...

Solution: 

Specialty Design designed and built a gantry press that automatically glued, positioned, assembled, pressed, trimmed and formed carpet into a finished product. Payback was significant due to labor savings and increased volume, quality consistently met demanding automotive standards and all safety issues were addressed.  Here is how Specialty Design’s system worked:

1. Carpet is positioned behind the Gantry Press and underlayment is positioned in front of it.  
2. The Gantry Press picks up the carpet and moves toward the underlayment. 
3. While moving, each of the individually programmable glue heads precisely spray the contours of form holding the underlayment. 
4. Once precisely positioned over the underlayment, the Gantry Press applies a specified downward force for a prescribed period of time to form the finished carpet contour. At the same time, excess carpet is trimmed and vacuumed away. 
5. The Gantry Press returns to the home position and begins the next cycle.

Specialty Design’s system required 2 operators (versus the previous 10) and reduced the customer’s cycle time by 250%.

Case Study: High Speed Pharmaceutical Cap Heat Seal Machine

Background:

A pharmaceutical manufacturer required a revision to their heat seal machine to achieve greater throughput and a more efficient count/per box system.

See Specialty Design's solution below...

Solution: 

Specialty Design modified customer's design and added a spin count and box shuttle unit.  Specialty Design's modifications increased the machine's output to approximately 950 parts/per minute.

Case Study: Machining Center Cell

Background: 

A manufacturer of die-cast aluminum floor panels required equipment to manufacture a better quality product to remain competitive in their industry.

See Specialty Design's solution below...

Solution: 

Specialty Design designed and built a complete 2-unit work cell that would:

• Automatically clamp the panels
• Machine the panels square
• Size and drill all holes around the inside periphery of the panels. 

The holes were drilled within .005" of true position.  This was accomplished using the following features:

• Precision rotary tables
• Milling heads on precision-powered slides
• Pneumatic & electric-powered drill-heads

Case Study: Robotic Press Feed System

Background:  

An automobile frame manufacturer required an economical automatic press loading device.  Specialty Design was positioned to build a machine for a much better value than a Detroit manufacturer. 

See Specialty Design's solution below... 

Solution: 

Specialty Design designed and built a press loading unit that integrated the following features:

• A fixtured rotary table
• Linear robot with vacuum, which allowed the unit to function within press cycle for maximum production