Automation Refurb: Case study 1

Refurbishment and retrofitting a highly specialised 3 tonne positioner.

Service Level

• Discuss client requirements
• Meet the customer
• Site visit
• Problems addressed and solved
• Planning and design
• Specification
• Lead time (done within 2 weeks!)
• Build schedule
• Delivery, install, commission, test, train.

The Challenge

This particular automotive client came to us because they needed ‘something like a welding position, but different.’ They needed us to supply a machine used to test the efficiency and effect caused to car engines whilst been turned at obscure angles, in a controlled environment. This would be done to an incredibly (almost unobtainable) high level of precision… and we had to deliver this machine within 2 weeks from date of order! No problem.

Our customer detailed the bespoke, custom built welding positioner and also the unique control panel system they needed. This involved Spectrum designing, building, and supplying a PLC computer control panel connected to the position, and integrated into their plant laboratory computer.

• Attach car engines to the positioner table with custom built jig brackets we designed and manufactured
• Tilt a car engine to near upside angles @ specifically 94° and 127°
• Rotate a car engine into exact positioners with precision control (done from a computer), and turn forward and reverse at high speeds during rotation
• Upgraded RPM
• The tilt gearbox teeth and motor control system had to precision, tight, and to one thousandth mm
• The engine would be running continuously during tilt / after tilt, operating @ full revs
• Monitoring probes and digital sensors to measure engine oil lubrication and fuel efficiency / consumption at obtuse angles
• Engine duty cycle tested and studied
• Control the machine from behind a shatter proof toughened glass screen (that we supplied) in a control booth for protection in the event engines blew up during testing
• Operate from a considerable distance away with a PLC control panel system connected to their computer
• Connect positioner to 34 digital monitoring probes and sensors
• Probes to interact and talk to the positioner tilt and turn system, as well as their computer
• We have done this before with a K-TIG automated system
• AC inverter frequency control tilt motor for variable speed tilt withing microscopic parameters and rapid stop / start control
• We designed and built the positioner control panel and the car manufacturer PLC computer control system, based on the customer’s requirements.

The Solution

Re-design the whole machine. For a lot of clients we have to sign NDA (Non-Disclose Agreements), therefore certain pictures can’t be uploaded. Essentially we took the core frame and functionality of a 3 tonne welding positioner and custom built a new 2-axis handling system, which met the client’s exacting needs for high precision and testing.

This build was quite an extreme case and done in such a short period of time, based on the customer’s quick turnaround requirements. With such demanding parameters for a non-welding related application (whilst connect to and interacting with other measuring equipment) this was seriously challenging. However, after lots of testing (and endless alterations!) we found a way, and it worked perfectly.

This control panel and PLC system was very, very advanced. It was quite interesting to see an old BODE positioner from the 70s turned into a state-of-the-art automotive automation, so we were quite proud to be associated with this particular manufacturer, and honoured to be involved in their production.

Refurbished and Retrofit Schedule

• New AC inverter frequency precision electronic control system
• Digital probes connection points built into the panel and positioner, and installed on site after delivery
• Panel built in accordance with BS EN 7671 18th Edition
• Brand new electronics inc. new cabling and limit switches
• New force-cooled AC motors / braked motors
• New mechanical drive systems
• All re-drilled and tapped
• New EN24T machined parts inc. shafts, keyways, and gears
• New chains
• New tensioners
• New phosphor bronze wear bush sleeves
• New belts
• New pulleys
• New couplers
• New taper locks
• New oil seals and fresh oil
• Shot blasted
• 2 coats of special primer paint (customer specification)
• 4 coats of high quality proprietary blue paint (made to manufacturer’s spec)
• Build, deliver, install, commission, tested. PASS

The result. Happy customer.

Trusted Support & Warranty

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