Miscellaneous Designs
DESIGNED BY: Young Solutions Inc.
Positive Pressure, Casting Impregnation System
A customer desires to use an impregnation system to reduce porosity issues with their castings. Standard submersion processes combined with vacuum have not produced the desired results. Young Solutions designed a positive pressure system which flowed impregnation fluid into the ports of the casting. The system was then pressurized while simultaneously rotating the part three hundred and sixty degrees. The scrap rate was reduced 72% over the prior process.
Fixture Location System for Six Axis Robots and Six Hundred Cubic Foot Fixtures
A customer utilizes several large six axis robots to process parts in a production line. The system works well until a new set up is required for a different part type. At each set up for a new part type all of the robots require re-programming. The customer suspects the root cause to be axis wear in the robots or the location of the very large fixtures used in the process. After a series of designed experiments and tests it was determined the level of wear in the robots was minimal. The problem was caused by the three dimensional movement in space of the fixtures during set up. With this knowledge an improved location system was developed to improve the locating repeatability of the fixture.
A system was also developed to measure the 3D variance in space on the large fixtures. Once this was complete an algorithm was developed to adjust the programs on the robots according to the fixtures new location in space.
Custom Pressure Decay Systems for Safety Related Hydraulic Parts
Several systems were developed to measure pressure decay on parts. The systems utilized simple control systems and part specific fixturing to facilitate production requirements..
Automated Mechanical Thread Cleaning Process for Any Size Threaded Bolt or Screw
A system was developed to mechanically clean large production volumes of bolts. Prior to this several systems like abrasive blasting, tumbling, die chasing, and a wire brush were all attempted with unsatisfactory results. These systems caused concerns with thread wear, cleanliness, and ergonomics. The new mechanical system proved quick and effective with the flexibility to handle any size fastener.
Control Systems for Hydraulic Presses
We have assisted several customers with press improvements. The most common improvement is verification of minimum forces applied during a press process. More sophisticated solutions provide controllers to program and automate numerous variables to allow multiple parts and criteria to be run with the same press.
Gauging System Evaluation for an Automated Ten-Station Inspection System
After a customer built their own ten station inspection system in house they continued to find non-conforA designed experiment was created in an effort to improve cylindricity on a precision honing operation. The data from that experiment resulted in a final process modification to utilize water miscible coolants to replace honing oils. This adjustment reduced thermal changes and distortions during the honing process, and significantly improved process capability.ming parts in their shipments. One of the steps we took while performing a root cause analysis involved a study of the inspection system. The data revealed this system to be incapable of properly determining whether a part was good or bad..
Process Capability Improvements for Precision Honing Operation
A designed experiment was created in an effort to improve cylindricity on a precision honing operation. The data from that experiment resulted in a final process modification to utilize water miscible coolants to replace honing oils. This adjustment reduced thermal changes and distortions during the honing process, and significantly improved process capability.
Hydraulic Valve Body Test Systems with Temperature Controls
