This customer contacted Quad Plus with concerns about their obsolete equipment controls and a custom-made rotary shear motor, which was supplied by a company that is no longer in business. Knowing that a controller failure would result in several weeks of downtime, the customer requested a solution before trouble hit. The project was further complicated because there were no existing control programs or electrical schematics; instead, we found a proprietary and dedicated “black box” with no description of its operation. Our solution included calculating the algorithm for electronic camming functionality and integrating new drives, motors, and controls. Remote monitoring equipment was also integrated, and a safety study was performed to identify areas for improvement. Along with spares for all the new systems, the customer also received detailed documentation for future reference.
This project allowed our team to proactively prevent a catastrophic disruption to the customer’s production and update and improve their current systems. Our engineers also demonstrated their skill and ability to manually calculate necessary algorithms and then create proper documentation from scratch.