Plasma Torch Study

Purpose: Design, build, commission, validate and install a fully automated, assembly system capable of producing light industrial; handheld and mechanized plasma torch consumables. System Description: The proposed solution provides higher efficiency elements for the consumables and the ability to take advantage of process improvements into higher throughput. The proposed systems allow specific processes to be…

Large Solar Panel Study

Purpose:  Design, build, test and install an automated systems to perform assemble two cross bar supports to main solar panel   System Description: Add two additional cross-supporting braces to current existing frames supporting solar panels. Those are achieved by taping, dispensing, placing, transporting and fastening stations to the current assembly system.  

Medical Device Connector Study

Purpose: Design and build a fully automated system to produce four models a connector used to connect standard pharmaceutical vials that allows for a simple method of reconstituting and diluting pharmaceutical drugs for intravenous delivery. The system used existing similar designs and processes already proven on previously built machines. System Description: Feed and Load Spike…

Stealth Body Filter Wrap & Press Assembly Case Study

Purpose: Design, build, commission, runoff and install (1) Filter Die Set and (2) Body-Filter Wrap Machines capable of producing Stealth Body-Filter Assemblies System Description: The Filter Die Set was implemented into Calvary’s Standard Filter Press Machine along with the Body-Filter Wrap Machine which includes Allen Bradley CompactLogix PLC for machine controls and Cognex vision system…

Automotive Rain Sensor Case Study

Purpose: Design, build, commission, validate and install an automated, assembly and test system capable of producing multiple model variants Rain Sensors System Description: A series of flexible modular assembly cells to provide component assembly and testing.  These modules are interconnected by robots and conveyors to form a complete assembly and test system for the Rain…

Consumer Products & Electronics Case Study

Purpose: Design, build, commission, qualify and install a fully automated, assembly system capable of producing Connector Assemblies. System Description: The system was designed, programmed and built to assemble and test a Connector Assembly. The machine is based on a Stelron Synchronous “Cam driven” PLC Precision Link Assembly Chassis. Two dedicated motors will drive the precision…