project innovation

We were recently contracted to develop a PLC-controlled potting dispensing and curing system for a major process instrumentation manufacturer. Their workflow includes high volume production of precision temperature sensors, which require highly precise, repeatable manufacturing processes that incorporate finely controlled thermal treatments.

A large number of the clients for this customer are Automotive Tier 1 and Tier 2 suppliers, which require best cost efficiencies possible while demanding high quality. Tied to a specific potting approach mandated by their customer base, this manufacturer came to us for our abilities in complying with many performance and quality expectations.

We designed and built an automated instrumentation potting system complete with full PLC control. In this all-new system, which included controls directed towards this customer's precision requirements, we were able to bring production rates past 200 parts per hour. More importantly, quality was improved and brought to a more consistent level than before.

We recently assisted a major manufacturer of industrial pumps in developing a thermal curing system capable of higher output than their original approach. Their manufacturing process, which involves the creation of sand castings to make high strength steel pump cases, is directly constrained by the cure time their equipment can provide. The previous system, which was convection based, did not provide acceptable quality or speed in the long term.

We answered with a solution derived from designs we've previously built for our marine customers. Convection drying was inadequate for their product coatings, so we developed a high-intensity infrared dryer for their processes. This approach cut down drying time significantly, from a previous average of one hour.

For this pump manufacturing customer, we redesigned the system to match their design dimensions, providing the same upgrades in thermal performance and process efficiency.

We were recently contracted by multiple customers looking to take advantage of our competence with Gas Infrared applications. This heating technology is one of the most powerful available, able to dry and cure very large, irregularly shaped objects. Few other thermal developers can design and build complete Gas IR systems for specific applications, as we did in the examples highlighted here.

For one particular customer, a large scale manufacturer of earth moving equipment, we developed a process thermal dryer for primer and paint on large pieces. This extremely large system can take bulldozer rams; dry the primer in 9 minutes, and then dry the topcoat in another 18 minutes after. In the customer’s previous system, which used unheated convection, the same amount of drying took 24 hours. For another customer, this one, a farm equipment manufacturer, we used the same technology to create a 6’ wide, 10’ high preheating bay for large powder-coated pieces. Gelling of the coating took 3 minutes alone.

Our Gas IR technology continues to be available for high-demand drying and curing applications, where the speed required or physical size would prevent other thermal processing manufacturers from delivering. We can design and build complete custom systems for your particular application’s needs, with controls tailored to your desired levels of precision and fine-tuned thermal processing. We also provide Gas IR heaters as modular units for use in your manufacturing systems and can design around other heating technologies as your particular needs require.

We have been contracted many times by our customer base to provide Custom Inline Ovens for commercial and industrial purposes. With these orders, we were usually selected for our reputation in handling highly nuanced customer designs and project requirements, or for our ability in delivering complete systems that remove the need for more outside work. We have constructed and delivered both small-scale batch thermal systems and large, continuous process thermal systems.

In one particular example, we designed and built a small PLC-controlled oven for curing of electrical potting materials. Incorporated into the design were an infrared heater, flight bar fixturing for robotic automated insertion and removal of pieces, and an overall layout that ensures a small footprint. The customer also required high precision curing control in the design, as the final components would form critical links in vehicular airbag systems. We were chosen explicitly for our ability to combine these heat treatment features with a highly specified physical design.

We were recruited to develop a combination infrared and convection design for a customer needing a complete system for powder coating. Starting off with their requirements, we built a dual system that incorporated overhead coating, allowing for a compact design without compromise. Our approach allowed them to cut the cure times by more than half compared to their previous powder coating system. This was an attractive advantage that they could then advertise to their customers. Additionally, our system was flexible enough for testing and evaluation of new coatings, moving a previously tedious external process in-house and, therefore making it more cost-effective.

We recently assisted a filter manufacturer primarily working with plastic end cap materials. Their manufacturing workflow requires attaching plastic end caps to pleated paper filter media with a strong, durable seal. Since welding heat must be localized to the cap itself, the customer was not able to find an off-the-shelf solution for improving weld quality and cycle time. They came to us directly because of our prior work on developing custom systems.

Based on their product specifications and application directives, we designed and built a custom plastic welder for their filter product. This system, capable of capping two filters at once, clamps the filter and end cap and uses a non-contact electric infrared heater that applies heat to the specific dimensions and areas that need to be welded. Largely automated, our custom system requires no interaction beyond loading and unloading of filter units. Our system provided a stronger, and more consistent weld while still significantly improving cycle times and even personnel safety.

We were recently approached by multiple automotive QA customers to develop a thermal solar simulation system for vehicle testing. Essentially simulating the hot sun on a clear day, these systems ensure that automotive components do not fail or perform unacceptably when faced with sunny weather. While we normally deal with high-intensity systems often targeted at process curing and drying, we were more than able to answer to the needs of these auto builders.

We designed and developed an infrared output heating system capable of delivering the temperature ranges and light intensities found on a clear day. Consisting of large aluminum or steel frames with multiple modular IR panels, this system was able to adjust for different size vehicles as well as different impact angles. It was also designed to run for long periods, therefore, able to simulate complete days of sunlight.