Succesful Projects

Mid-sized commercial truck manufacturing plant.

Executed the redesign and optimization of a 30+ year old pretreatment and e-coat line.

This was performed during multiple shutdowns involving crucial time constraints and much planning.

TOP: Picture illustrates the Anode system new SS supply header, valves and hoses.  As well as the coolant return system.

LEFT: All of the Anodes were replaced with a new design. The newer design created a complete redesign of the coolant return system.

RIGHT: The agitation flow of the e-coat tank was completely redesigned. New headers, and nozzles. Including drilling and modifying the main tank.

TOP: The filtration system was upgraded. This included removal of the outdated filters. New filter canisters were plumbed in place and leak tested.

LEFT: Spray headers were fabricated and added to two rinse tanks. Proper aiming and leak tests were performed.

Right: New Drip Trays were fabricated and installed. The project included redirecting the drippings to different tanks.

Pre-Treatment Filtration Upgrade

Integrated 2 new Hydrocyclones. Included fabrication and installation of 6” SS piping, control valves and insulation.

Replaced existing worn gusher pumps with higher capacity pumps. New piping to the pumps.

Designed and fabricated a pressure bypass system including control valves and insulation.

Integrated new soft-starter panels with VFD’s to accommodate the higher capacity pumps. Included complete high voltage and low voltage wiring.

This new production line included a Stacker Crane.

(A Stacker Crane is an automated component storage system.)

We installed 5 main control cabinets. 2 of which are completely mobile and moved with the crane.

TOP: Overview of the storage system. The mobile control cabinet is in the background. Completed all of the connections to the sensors, encoders, motors, sub-panels and communications.

LEFT: Motor Encoders are wired to assure accurate position of lifter to storage finished parts into Stacker Crane.

RIGHT: Mobile Control Panel is mounted to the Stacker Crane, included an optical data PROFINET system to communicate with main panel.

This manufacture required additional shuttles to increase their production capacity.

These shuttles are used in the Pre-treatment and E-Coat.

The scope for included both mechanical and electrical expertise.

This is a Single Arm shuttle design. We assembled and installed three new Eisenmann E-Shuttles and followed through all the way through the commissioning process.

This manufacture required additional shuttles to increase their production capacity.

One existing shuttle showed signs of aging and required an overhaul.

These shuttles are used in their Pre-treatment and E-Coat line.

Double Arm Shuttle system.

We carefully disassembled and overhauled one Eisenmann Vario-Shuttle.

We assembled and installed two new shuttles.

The scope for both installation and overhaul included both mechanical and electrical expertise.

 Provided commissioning support.

This component manufacture required the replacement of a worn section of a conveyor.

This conveyor fed the Pre-treatment and E-Coat line.

The working conditions were less than favorable.

In addition to the replacement conveyer section, we fabricated a service window to allow the maintenance team to service the conveyor chains.

We worked with Eisenmann Inc. and successfully completed the task during a short shutdown.

This manufacture required replacement component transfer racks.

The existing racks were out of specification and the robots could not load or unload the components.

These rack are used in their Pre-treatment and E-Coat line and are exposed to significant heat cycles.

We worked with our CAD designer, optimized the design.

The new design increased the strength, but more importantly solidified the repeatability of maintaining the critical RPS points during the manufacturing of the racks.

The redesigned racks allowed Gestamp to for the first time use the robots not only to load but also to unload the components from the racks.