These are some examples of assembly and contract manufacturing we have done.
We have Coil Winders to wind most any type of coil up to 4 inch diameter. Our winders are four spindle winders, fully programmable to precisely and efficiently wind the coils to your specification. The coils below have a 60Hz and 50Hz wind with over 2000 total turns and the wire has to be twisted and spot welded to the terminals. The customers cost for labor doing these themselves is $0.23 each more than we charge them. This gives them a savings of just over 35% with us doing them. The volume on these coils is between 5,000 and 14,000 coils per week.
This is a lamination that we weld for the same customer that we wind the above coils for. We built a machine to automatically weld the laminations on each side using two tig welders driven with a stepper motor. The laminations are 0.025" thick each. The number of laminations can vary between 25 and 80 depending on what size motor they will be used for. The machine will feed out the correct number of laminations and line them up precisely within 0.0005" before clamping them in place and welding. There is no filler added to the weld. The customer was riveting these laminations together. The weld is a much stronger and more precise way to hold them together. The volume for these is between 10,000 and 28,000 per week.
Spark plug terminal for the automotive industry. We built machines to insert the metal clip onto the terminal as the parts are exiting the punch press at speeds up to 550 parts per minute. These machines use probes, sensors and laser measurement to ensure all terminals have correctly installed clips. Zero defects.
We built these machines to drill holes in hydraulic valve cartridges. This machine uses a Fanuc 5 axis robot to pick the part out of a pallet then drill the correct diameter hole at the specified angle then return the part to the pallet. This machine drills many different parts with no setup time, just select the desired part # from the list on the control pad. There are 20 different air drill motors with each having a different diameter drill to eliminate time consuming changeovers.
Adjust screw for a hydraulic valve. We built this machine to assemble the adjust screws. The machine presses the spacer on, snaps on the wire clip, threads on the nut, and installs the o-ring and backup-ring. It inspects for missing and incorrectly installed components. If something is wrong, it shoots the screw in the bucket on the right. If everything is correct, the screw drops thru the table into a tube and is shot into the bucket on the left with a blast of air. The yellow bars are Light Curtain and 3 mirrors protecting the full parameter to pause machine if someone reaches into the work area.
These are just a few of the rollers that we assemble for the leader of wheel assemblies to the window and door industry, P.E. Delmar. Their sales are worldwide and they have been in business for over 50 years. Their rollers are 100% American made. www.pedelmar.com
This is a power cable for a Tig Welder. We run a copper cable thru the rubber hose and crimp the connectors on the ends. This allows the power and gas to flow thru the single hose.
This is a gas hose for a Tig Welder. We cut the hose to length and crimp the fittings onto the ends.