Machining Solutions
Telephone Cable Splice Box Gasket Slitter
The Challenge
A supplier of connection devices to telephone companies required a system to “slice” thick rubber grommets for accommodating a variety of cable diameters. These grommets are typically used in splice boxes that are hung from telephone poles. The technician uses the grommet by removing a sufficient number of rings to match the cable size being installed.
The Solution
Creative Automation designed and manufactured a special lathe and carbide slicing knife to cut into solid blocks of rubber. An operator places an uncut blank onto the systems vacuum chuck. When the start button is pressed, the spindle is rotated at a controlled rate of speed and a specially designed carbide slicing knife is plunged into the blank. The depth of cut, spacing and number of cuts is pre-programmed into the systems computer. The operator simply selects the part number of the part to be processed.
Air Bag Component Deburr and Inspection Station
The Challenge
A manufacturer of air bag components needed to deburr parts made from a screw machine operation. The deburring process required the clean removal of a parting mark and the chamfering of a drilled hole. The production required the processing of 45 parts/minute.
The Solution
Creative Automation designed and fabricated a turret indexing, second op machining system to perform the above operation. Components were automatically fed and loaded onto the machines turret and after the operations were complete, the parts were automatically offloaded. The operators’ task was to maintain a sufficient supply of components in the supply hopper, which held enough parts to operate the system for 2 hours.
Multi-Purpose System for Threading PVC Fittings
The Challenge
A plastic fitting manufacturer had a problem molding schedule 80 threaded fittings. In order to get the required tolerance, the molds needed to be clamped for an extended period of time resulting in slow production and tolerance issues.
The Solution
Creative Automation solved the problem by designing and fabricating a special system to tap sizes ranging from ¼” NPT to 1 ½” NPT. The system was designed using an indexing turret that enabled an operator to load fitting bodies a location away from the machining operations. The system was built with replaceable nests to handle a wide variety of fitting sizes as well as fitting configurations.
Aerospace Fastener Cross Slotter
The Challenge
An aerospace fastener manufacturer required a process for cross slotting special fasteners that could not be made on his CNC lathe. Further there were a variety of sizes which were typically processed in small quantities.
The Solution
Creative Automation designed and fabricated a 6-station, dial-type machine utilizing standard collet closures for securing the fasteners and allowing quick and easy changeover from one size to another. The 4 cross slots were machined at separate stations using carbide slitting blades driven by precision spindles and slides. The operator’s task was to load components with the remainder of the process, including unloading, occurring automatically.
Automated Canister Drilling and Tapping System
The Challenge
An aerospace manufacturer required the precise drilling and tapping of 176, 10-32 holes in a multi-component assembly. Their current method of manufacturing was to fixture the components and use a combination of a CNC mill and special drill presses. Production time was 80 minutes per assembly. The production requirements required them to produce 1 assembly every 10 minutes.
The Solution
Creative Automation designed and fabricated a custom 26-spindle drilling and tapping system. The system was built using a granite plate as a base and precision weldments for mounting the spindles. A shuttle carriage moved the part and fixture left to right, while a rotary indexer performed the 4 positions of rotation alignment. The last 4 spindles on the left are set to 5° and 10° angles to accommodate hole locations on the front end of the assembly. Production time was reduced to under 10 minutes per assembly.