INDUSTRIAL AUTOMATION SOLUTIONS

Transcription

1 COMPTROL INCORPORATED INDUSTRIAL AUTOMATION SOLUTIONS Components Systems Services SETTING THE NEW STANDARD FOR INDUSTRIAL AUTOMATION PROVIDERS... TOTAL IN-HOUSE CAPABILITY Company Overview Machining & Manufacturing Services Engineering & Assembly Services Automation & Equipment Upgrades Engineered Automation Solutions Industrial Automation Experience Linear Motion Products & Systems Tension Control Products & Systems Weight Verification Systems

2 TODAY S INDUSTRIAL TECHNOLOGY REQUIRES MORE THAN A SUPPLIER WHO JUST SELLS COMPONENTS It requires a company with the products, application experience, engineering, and manufacturing resources to make it work. That company is Comptrol Incorporated. Comptrol Incorporated is a leading manufacturer, and provider of industrial automation components, systems, and services. Comptrol 53,000 square foot facility in Cleveland, Ohio houses sales, engineering, and manufacturing operations. Since 1952, the key to our success and growth has been our commitment to provide our customers with the industrial technology and technical support they need to meet their project objectives and specific application requirements. So over the years, Comptrol did more than just expand our product lines. We also expanded our engineering, manufacturing, and integration capabilities to keep pace with technology and the growing demand for packaged automation and turnkey systems. MANUFACTURING Comptrol s machine shop is well equipped to handle all phases of close tolerance prototype and production run parts. ENGINEERING Comptrol mechanical, electrical, and software engineers are experienced in all levels of industrial automation design and integration. Our sophisticated CAD network expedites design and communication between engineers. ELECTRICAL ASSEMBLY Comptrol skilled electrical technicians handle all phases of board, panel, and system level assembly. MECHANICAL ASSEMBLY Comptrol assembly services go beyond the nuts and bolts of putting parts together. Our experienced assembly teams precision align, adjust, calibrate and test every Comptrol assembly and system to insure that what looks good on paper, fits right, and functions properly as an integral part of the overall assembly or system. 1 Copyright 2008, Comptrol Incorporated Printed in U.S.A. All Rights Reserved Form D

3 TOTAL IN-HOUSE CAPABILITY PROVIDES SINGLE SOURCE RESPONSIBILITY AND PROJECT INTEGRITY Today Comptrol Incorporated sets a new standard for industrial automation providers. A standard defined by a company with the products, application experience, and in-house resources to assist customers with any or all aspects of a project including: Concept and application assistance Technology and product specification Project planning Mechanical and electrical design Software development Component manufacturing and fabrication Mechanical and electrical assembly Installation supervision and assistance Training and documentation Whether our customers need a standard component, a modified or custom assembly, or an integrated turnkey system, they know Comptrol Incorporated will deliver the Quality, reliable products Experienced application assistance Complete engineering and technical support they need to optimize the efficiency and performance of their industrial processes and equipment. TECHNICAL SUPPORT Comptrol customer service and application engineers provide immediate product specification and technical support information. Computerized order entry, inventory control, and EDI communication link expedites processing customer inquiries. RECONDITIONING SERVICES Comptrol ballscrew reconditioning services restore customer units to like new condition. STOCK DELIVERY Comptrol offers stock delivery of over 120,000 industrial components. PRODUCT EVALUATION Comptrol is constantly testing and evaluating new products to help our customers keep pace with new and developing technologies. Two inhouse environmental chambers test the effects of temperature on product performance. TRAINING Comptrol in-house and customer site training seminars keep customers up to date on new products and technologies. 2

4 MACHINING SERVICES... FROM PROTOTYPE TO PRODUCTION Comptrolʼs in-house machining capability gives us close control over the quality and production of all Comptrol manufactured products and systems. It also provides our customers with a source for the additional machining capacity and capability they may need for prototype and production run parts. Comptrolʼs machine shop is well-equipped with high performance CNC and conventional machines to handle all phases of close tolerance production of small intricate parts as well as larger, more complex part geometries. The versatility and accuracy of these machines is enhanced by our experienced, quality conscious machinists. Their programming and machining skills optimize each machine s production capability to maintain Comptrolʼs high quality standards. Machines are linked via our shop floor computer system to facilitate programming and minimize setup time on new or repeat runs of standard, modified, or custom components. Comptrol s machine shop is well equipped to handle all phases of prototype and production run manufacturing. Okuma 4-Axis CNC Turning Center Norton Surface Grinder with 9 foot bar support Powermatic Drilling Center Warner & Swasey 2-Axis CNC Turning Center Monarch CNC Machining Center with pallet changer Three Hurco CNC Machining Centers Hurco CNC Milling Machine Lagunmatic CNC Milling Machine Chevalier CNC Surface Grinder Two Bridgeport Milling Machines Ex-Cel-O Milling Machine Cleveland Engine Lathe Colchester Engine Lathe DoAll Vertical Band Saw Everette Abrasive Cutoff Peerless Horizontal Cutoff Saw Comptrol has the in-house production capacity for machining small, intricate parts and large, complex part geometries. 4-axis CNC turning center with bar support for machining ballscrews. Large capacity CNC machining centers with pallet and tool changers. Shop floor network links machines and facilitates programming. 3

5 MECHANICAL AND ELECTRICAL DESIGN AND ASSEMBLY SERVICES Comptrolʼs in-house engineering and assembly capabilities provide each customer with the level of technical support needed to meet their project objectives, from sizing and selecting components to designing and building turnkey automation solutions. We ll build to your prints, or assist you with any or all of the mechanical or electrical design and assembly. Comptrolʼs multi-disciplined engineering staff enables our design teams to address all aspects of a project including: Mechanical design and assembly of linear motion and transfer systems, automated equipment, pick & place devices, machine base frames and assemblies Electrical design and assembly of control circuits, panels and enclosures to NEC, NFPA, UL, ULC, or customer defined specifications and standards Comptrol electrical assemblies receive a thorough point-to-point functional check and power-up test. Programming and networking for motion control (servo or stepper), PLC, operator interface, SCADA, robotics, and PC based applications such as Visual Basic, C, and open I/O networks Their experience, combined with the craftsmanship put into each project by our skilled assemblers and technicians, insures the quality and integrity of the system at the assembly level before installation. Programmable vertical lift assembly with Comptrol linear positioner. Inspection system designed and built by Comptrol integrates electromechanical part handling, electronic ID and OD gauging, weight verification, and PC-based control. Left and right hand threaded ballscrew assembly with end support bearings and protective covers. Multi-bay control enclosure built to customer specification and prints. Electrical panel and enclosure design and assembly integrate motion control technology, motors, drives, PLCs, operator interfaces, and open I/O network. 4

6 AUTOMATION AND EQUIPMENT UPGRADES... INCREASE PRODUCTIVITY AND PROFITABILITY The old adage, If it ain t broke, don t fix it., doesn t always apply when the efficiency and performance of the equipment has a negative effect on quality, productivity, and profitability. Comptrol technology upgrades and retrofits provide a practical, cost-effective method of improving the operating performance, accuracy, and versatility of existing machine tools and process equipment. Today s high-tech motion control, process monitoring, and industrial control technology makes it possible to simplify original equipment designs to reduce maintenance costs and setup times, while providing tighter process and quality control. Comptrolʼs experience with all facets of mechanical, electronic, pneumatic, and hydraulic component integration, enables us to provide our customers with a complete package which incorporates technology from the leaders in the industry: Allen Bradley Bimba Control Techniques Cutler-Hammer Eaton Delta Tau Multi-axis retrofit package replaces original motors and gear box transmissions with state-of -the-art servo drive systems. Comptrol designed and built mounting adapter kit and electrical subpanels to simplify installation on existing equipment. Injection mold equipment upgrade incorporates two Comptrol linear positioners with custom slide assembly. Emerson Motion Control Indramat IDT Nematron Superior Electric Reliance Electric GE Fanuc Intellution Modicon Parker Hannifin Prolog Warner Electric... and more. Servo upgrade for conveyor system includes Comptrol engineered operator panel, enclosure, and motor mounting brackets. Comptrol machine tool retrofit replaces cam driven slides with new programmable multi-axis servo driven system, operator console, control, and electrical control panel. Interfaces were developed to interface system with existing main motor, lubrication, hydraulic systems. Automated positioning stop for metal cutting saw with Comptrol designed driven ballnut rail assembly and programmable control. 5

7 ENGINEERED AUTOMATION SOLUTIONS OPTIMIZE PERFORMANCE AND CAPABILITY Engineering an automation solution from the ground up tailors the solution to meet specific customer-defined production, operating, and design parameters. It also makes it possible to combine multiple tasks or operations into a single operating system, without the limitations imposed by general purpose equipment. Comptrol engineered automation solutions provide the built-in capacity and capability companies need to increase the productivity, efficiency, and throughput of their operations. Our ability to evaluate the entire process ensures the solution will not only achieve the project objectives, but also function as an integral part of the overall operation. Robotic part handling and stacking system integrates gauging and drilling operations under centralized control. Comptrolʼs total in-house capability provides companies with a single source for designing and building turnkey automation solutions. So that instead of buying do-it-yourself, make-them-fit components from multiple manufacturers, our customers are investing in a complete, ready-to-install automation solution designed and built by one company, Comptrol Incorporated. Two axis radial positioning system and control package for inspection probe. Three axis indexing table for automatic screw setting application. Comptrol two axis slide and control designed and built to meet specific application requirements. Automated packaging system integrates Comptrol designed positioning system and two fourstation pneumatic pick and place stations with entrance and exit conveyor system. 6

8 THERE S NO SUBSTITUTE FOR EXPERIENCE WHEN IT COMES TO INDUSTRIAL AUTOMATION Industrial automation comes in all different shapes and sizes. The key to successfully applying it is selecting the technology that is best for the application and knowing how to integrate it with other components in the system. That s where Comptrol product lines, application experience, and engineering know-how pay big dividends for our customers. Comptrol product lines allow us to draw from a broad spectrum of new and existing products and technologies to address each customer s specific application requirements in industries such as: Automotive Battery Bearing Food Processing Lumber Automation upgrade with servo driven tooling slides, safety light curtains, and new electronics and operator interface package. Machine tool retrofit package with Comptrol ballscrew assembly and new drive system. Machine Tools Medical Equipment Metal Processing Material Handling Paper, Film, & Foil Plastics CNC operator control console. Rubber Textile Wire The experience we ve gained working with both large and small OEMs, end-users, rebuilders, and integrators associated with these industries is an added benefit we pass on to our customers. Lathe control upgrade with new motor/drive package and operator control. Material handling system incorporates modified Comptrol positioning system. Small part sorting and inspection system incorporates Comptrol designed part handling system, operator control station, control hardware and software. 7

9 LINEAR MOTION PRODUCTS AND SYSTEMS FOR PRECISE POSITIONING ACCURACY Comptrol Incorporated provides our customers with a single source for all their linear motion needs. We offer a wide variety of standard, high performance products designed and built to meet the rigorous demands of today s industrial applications. These products include: Ballscrew components and assemblies High speed linear positioners Linear rail assemblies & components Single & multi-axis slides or positioning systems Comptrol Ballscrew products include inch or metric ballscrews, single or preloaded ballnuts, end mounting bearing supports, and complete ballscrew assemblies. Servo or stepper motors, drives, and controls And with our in-house engineering, manufacturing, and assembly capabilities, we can provide our customers with modified or custom components, assemblies or systems they need to meet their application requirements. Comptrol s Linear Positioners are available with in-line or parallel configurations with stroke lengths up to 49 inches and thrust capacities up to 14,800 pounds. Comptrol Bearing Blocks are available in base, flange, or cut-off flange mounting styles with single ball bearing, back-to-back angular contact, or spaced bidirectional angular contact bearing. Comptrol Programmable Linear Thrusters have a 25 pound load capacity and are available with stroke lengths up to 24 inches. Units can be configured for either servo or stepper drive systems. Comptrol Linear Slide components include shafts, one or two rail shaft and end supports, linear bearings, and carriages. Complete manual and ballscrew driven systems are available. Comptrol single or multiaxis positioning systems offer a unique combination of load carrying capacity and positioning accuracy utilizing servo and stepper based control systems. 8

10 TENSION CONTROL PRODUCTS... AN INDUSTRY STANDARD ON CONTINUOUS STRIP PROCESSING LINES Comptrol tension transducers, indicators, and controls are an industry standard on continuous processing lines where accurate, dependable tension measurement and control are key factors in maintaining consistent quality. The advantages of our patented tension transducer designs have been proven in thousands of applications in the paper, film, foil, plastic, metals, rubber, textile, wire, and converting industries. Comptrol offers a complete line of tension transducers, indicators, and controls including the AC10/20 digital tension measuring systems. Side or base mount models are available with load capacity ranges from 4-35,000 pounds. Comptrol tension transducers are designed to withstand overloads up to ten times their rated load capacity. Comptrol patented transducer designs allow them to be mounted at any angle around the axis of the measuring roll with any wrap angle. They work equally well in either tension or compression making them easy to adapt to any new, retrofit, or replacement application. Comptrol transducers are known throughout the industry for providing a stepless, high level voltage output signal direct from the transducer to a tension indicator, drive, or system controller. 9

11 QUALITY VERIFICATION WEIGHCELLS FOR 100% CONTINUOUS PROCESS MONITORING AND CONTROL Comptrol Weighcells and controls provide a fast, accurate, nondestructive method of monitoring and controlling quality for continuous manufacturing, assembly, or packaging processes. Capable of detecting weight variations as small as 0.1 gram, these rugged industrial units provide an effective method of in-line or off-line pre-process or post-process quality verification in fill-to-weight, machine-to-weight, part presence, and sorting applications where the dependability of the Weighcell is a key factor in maintaining consistent product quality. Standard single Weighcell module. Custom, modified, and multiple Weighcell modules are available. Comptrol Digital Weighcell System weighs both ends of a connecting rod simultaneously. Post-process weigh station integrated as part of for machine-to-weight process. Comptrol developed the software interface, control screens, and tool offset program for third party workstation. Screen shown monitors flow of parts through system operations. Inspection subsystem designed and built to integrate into customer s existing process line. Package included control system to monitor part delivery, weighing and sorting operations. 10

12 COMPTROL INCORPORATED 9505 Midwest Avenue Cleveland, OH Phone: or Fax: Serving Industry Since 1952 Comptrol Incorporated is a full-service manufacturer of tension measuring, linear motion, and quality verification products and systems. We are also a major distributor of industrial control products. Since 1952, Comptrol has earned an international reputation for providing customers with quality reliable products, experienced application assistance, and complete engineering and technical support not only for the products we manufacture, but also for the products of the leading manufacturers we represent.