Advanced Wire Saw / Winding Machine - Colorado Springs, CO
A high-precision wire saw required eight coordinated axes, CNC-like behavior, and a complete rethink of control-loop assignments. The original architecture used the wrong loop methods and poor prototype workmanship. The redesign separated spool torque control, web speed control, and cam-based traverse behavior to create stable coordinated motion as well as addressing the cabinet layout.
Wrong motion architecture and axis role assignment.
Different axes must serve different physical roles.
Stable, precise cutting behavior with CNC-like coordination.
ASU Gammage Auditorium Broadway Rigging Modernization - Tempe, AZ
A failing analog hydraulic overhead rigging system was transformed into a modern servo-driven platform with 32 large 8 kW servo axes, gearbox-driven hydraulic control, and a Beckhoff IPC-based control architecture. The result supports precise, repeatable, safe movement of heavy overhead stage loads for major productions and events.
Legacy analog/DC controls in a safety-critical environment.
Incremental upgrades were not enough; the architecture needed full modernization.
High-precision, repeatable control of heavy overhead loads.
Envelope Converting Plant Modernization – Toledo, Ohio
Over a long-term partnership, ten envelope presses were upgraded with servos, modern PLCs, and improved operator interfaces. The work extended beyond the machines to plant workflow, process piping, material delivery systems, industrial networking, and custom production-management software for downtime tracking and maintenance cost reduction.
Legacy equipment and fragmented plant systems.
Machine upgrades alone were not enough; the plant had to be redesigned as a system.
Greater visibility, better maintainability, and long-term modernization.
Filter Media Production & Treatment - Colorado Springs, Colorado
A conceptual light weight web uniwnd / rewind system was taken from manual control and zero automation, to full process automation in under two months. Resulting in a now 7 year old relationship that has grown to become yet another long term partnership.
Overcome non-existent automation and manual production
Additive measures would not suffice, a new machine needed to be constructed from the ground up.
Fully automated unwinding, tension control, treatment, slitting, web alignment, and rewinding.