Machine Systems Design
With over 30 years of wide-ranging industrial machinery design, analysis and fabrication experience, we can address your need for anything from design of a "one of a kind" custom machine, to "reverse engineering" restoration and improvement of your older or "discontinued" machinery.
Above, top left, a roller coaster car hitch system, designed by CES, providing 3-axis rotary motion (pitch, roll and yaw) in a compact, high strength and lightweight package.
Above, top right, a work stand, designed by CES, for factory qualification test of a rail-mounted vehicle.
Above, lower left, a portion of a unique wire processing system, designed by CES. This system provides induction heat-treatment of metal "superalloy" microtube while accomodating length changes during treatment.
Above, lower right, a custom support stand structure, designed by CES, to accomodate the weight, vibration and thermal movement exhibited by the cylindrical device (a special low frequency "siren" used for an industrial cleaning application).
Shown below is a "Geneva" wheel and driver set, used to convert a continuous rotary input into an "indexed" rotary output. Many variants of this mechanism exist. When used at high-speeds, we must anticipate elastic "windup" and oscillation behavior which can cause problems unless controlled. CES has strong background in Geneva indexing systems design.
Also shown is a Hammer Disc wheel, one of many such units used in rotary rock crushing machines.
Competent design and performance prediction of such machine elements requires detailed understanding of material behavior under shock loading, heat treatment, tribology, centrifugal dynamics, among other considerations. CES has years of application experience in these areas.
Shown below, an industrial batch prep vessel system for mixing of high-viscosity fluids, designed by CES for a building products manufacturer. Two impeller variants were designed, an Archimedean screw type, and a propeller type with variable-pitch blades. Note that both types use sidewall and bottom scrapers to achieve complete blending regardless of ingredient density.
In the design of amusement ride vehicles and track structures, passenger safety and long term structural durability is critical. CES can provide your project with design and stress analysis of critical structures.
It is a relatively straightforward matter to design components to withstand known static loads. But the larger challenge is to properly design components against failure under long-term cyclic loading. Such "fatigue" failures can occur without warning, after years of service, and are often catastophic.
Prevention requires a thorough understanding of material endurance limit, proper weldment design, corrosion control, heat treatment application, and control of hydrogen embrittlement when using high-strength metals. CES considers all these factors when designing your critical structure.
Tooling design and fabrication is another CES specialty. Shown below are two tools, designed by CES, for fabrication of a filament-wound carbon fiber fuel tank for a spacecraft.
Pictured at far left below, is a mold tool for layup of the tank "skirt"; in the middle, a test stand for the assembled tank.
Epoxy-based composite structures such this tank require vacuum-bagging and autoclave curing while on the tool, so both tools were designed to be both autoclavable and rigid.
The "layup" of filament-wound components requires computerized control of filament position, distribution, and tension during the winding process. At far right, below, is a special tool, designed by CES, to align and orient the filament array during the process.