Replacement coater existing line

Goal

  • Design and supply aqueous transfer type coater with Meyer rod spreader.
    • Single sided, 1200 fpm, 70” web width.
  • Design based on customer’s in-house built developmental machine.
    • Improved precision of coating application.
      • More rigid frame.
      • Micrometer gap adjust.
      • High quality rolls & bearings.
    • More robust mechanical components for 24/7 operation.
    • Improved access for cleaning and set-up.
    • Corrosion free construction.
  • Design to fit into existing coating line.
    • Installed on third story of mezzanine.
    • Weight and ease of installation very important.
    • Use existing stock of Meyer rods.

Starting Point

Existing coater was built in house to confirm concept and prove out coating materials. No drawings or documentation was available.
Continuous production required a more robust machine that:

  • Held adjustments.
  • Allowed more precise adjustment of coating roll gap.
  • Used corrosion resistant materials.
  • Allowed faster servicing for cleaning coating tray when changing coatings.

Features

  • All AL frame.
  • SS Coating rolls & pan.
  • Eccentric fine adjust for Meyer rod height.
  • Dial indicators for coating gap setting.
  • Pneumatically raised coating tray.
  • Slide out coating tray for easy cleaning access.
  • Walk through platform for operator access.
  • Built in drip catch tray.

Scope of work

AMD provided turn-key supply.

  • Measuring of existing machine and space.
  • All engineering.
  • Fabrication and assembly.
  • Delivery and installation.
  • Commissioning support

Non-woven tube former line for UK plant

Goal

  • Provide complete turnkey, pre-tested production line for continuously forming a double wall tube of industrial felt.  Outer skin of coated material to also have a bonded seam tape over the joint.
  • Certified to meet CE standards for machinery safety and electrical performance.
  • Design for convenient packing into standard overseas containers for economic shipping.
  • Utilize best features of existing production lines while incorporating several new process and design advances.

Starting Point

The customer had multiple existing lines representing several generations of process development. Extensive time was spent with the operators and engineers learning the important variables of the process and the strengths and weaknesses of the existing machinery. A detailed specification was developed for the new line. Consideration was given to what the operators were already used to for procedures. Service and effectiveness of various components were considered and specifically called for where appropriate. The installation location was not fully finalized so the design was developed that could accommodate a single level or 2 story installation to save space.

Features

  • Self loading shaftless unwinds eliminate operators lifting of air shafts.
  • Flexible tooling allows wide range of single or double wall tube formation.
  • Modular design allowed shipping entire line in 5 major pieces.
  • All aluminum extruded strut framing allows easy future modifications and upgrades.
  • Central operator control console with touchscreen allows operator monitoring and control of all critical parameters from central location.

Scope of work

The entire line was fully modeled in 3D in Solid Works CAD software.   All machine sections were designed to fit in a standard overseas container.  All components were selected to be CE certified where applicable as well as readily supported in the UK.  An international consultantancy was hired to assist in obtaining CE certification.

The controls were engineered to operate on 50 or 60Hz to allow full testing prior to shipping.  The test facility main power supply was converted to the voltage used in the final installation location.  Plant personnel participated in the final performance testing before shipping.  This resulted in several valuable suggestions that were implemented and tested prior to shipping.

Die loading jack

Goal

  • Improve safety and convenience for set-up personnel.
  • Provide easy to use stable jack for lifting steel rule die plates into position in a blanking press.
  • Provide very robust tool to withstand abusive plant floor working environment.

Starting Point

Plant personnel requested an easier and safer method of lifting steel rule die plates into position for bolting to press platen.  Existing jack has too heavy and tended to let the die plate tip.  Frequent product changes resulted in too much effort and too much time spent during change-overs.  Existing jack required frequent repairs or replacement.

Features

  • Pneumatic operation requires no operator effort.
  • Lifting and lowering speed easily controlled.
  • Large footprint provides excellent stability.
  • Aluminum construction is strong but light weight.

Scope of work

Existing die plate loading operation was observed and existing equipment inspected.  A pneumatic design using standard off the shelf parts was conceived.  A simple functional mock up was built and demonstrated to plant personnel. Upon approval a permanent aluminum plate version was built.  Firestone Airstroke pneumatic actuators used for long life.

  • No seals to fail.
  • Very tolerant of shock loading and side loading.

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