Beyond Standard Customer Solutions

Table of Contents

Conveyor & Special Casters

Fabricating Concepts

Conceptual Innovations Engineering

Reaction Industries

Special Machining

Customer Testimonials

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Conveyor & Special Casters

57 Series Customer: Automotive Manufacturer Application: Industrial Carts in a forklift free environment Issue: The Company was moving toward a forklift free environment and needed a product that was durable, easy to roll and quiet. Solution: After rigorous testing done by the company it was determined that the Caster Concepts caster required 25% less force to move loaded carts as well as reduced noise and was the best ergonomic choice. The company has standardized the use of this caster within their facility and continues to work closely with the team at Caster Concepts.

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Automotive Trolleys

Customer: Automotive Conveyor Distributor Application: Automotive conveyor system Issue: The end user was experiencing a short life with the trolleys in their conveyor system causing them to spend large amounts of money and time to correct the problem. The original design was rubbing on a steel track causing the frame to wear due to the steel on steel friction Solution: The team at Caster Concepts was able to work with the distributor to double the life of the trolleys. The largest improvements were made in the design of the frame. The new design completely eliminated the steel on steel friction.

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Customer: Automotive Manufacturer Application: Heavy duty dollies Issue: Noise and Collision damage to trailers and other objects as well as low use life expectancy of the dollies Solution: A shock absorbing caster with a T/R compound wheel to quiet the process as well as a caster equipped with a sprocket to allow the caster to be steered The customer was having difficulty controlling the steering of the carts as well as the noise created by the carts. Caster Concepts was able to reduce the noise by using a shock absorbing caster as well as the T/R compound wheel. To correct the steering issue Caster Concepts welded sprockets to the yoke base to allow the casters to be steered and provide truer tracking of the dollies.

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Customer: Automotive Assembly Plant Application: Mini Skillet system for Instrument Panel assembly line. Issue: The instrument panel mini skillet line is a highly automated assembly system that incorporates Automated Guided Vehicles and Robotic handling of parts. The skillets are considered tooling and are required to be precisely located in order to correctly interface with the automation. Material and debris on the floor could impact the locating of the tools as they moved through the manufacturing process. Solution: For consistency in locating the tool, Caster Concepts designed a guide wheel that would precisely engage the assembly track and assure proper location of the tooling throughout the assembly process. Track Brush wipers were incorporated into the Toe Guards to minimize the impact of foreign debris or objects interfering with the travel or location of the tool.

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SPD061110 Customer: Aerospace Manufacturing Application: Large finishing mandrel used in sanding section 41 (Cockpit, Galley, and Crew Quarters) of the Boeing 787 aircraft Issue: .Load was extremely fragile and heavy at 35,000 per caster. The floor had minor variations in surface height. Space limitations would not allow for caster shift while swiveling. Solution: Caster Concepts worked with the Boeing Offload Tool Design Engineering house to develop a double swivel caster to eliminate the castering effect of the tool as the casters went to swivel. A super high capacity precision slew bearing was used for the main swivel while the 35,000 capacity 99 series swivel section was used as the secondary swivel bearing. An Oscillating axle was incorporated into the design to allow for inconsistent floor surfaces.

SPD070606

Stubroller

Customer: Automotive Manufacturer Application: Skid conveyor drive wheel Issue: Supplier of the conveyor was no longer in business. Ford needed to repair and replace 180 drive wheels. Solution: Caster Concepts was supplied with a sample of the existing product to reverse engineer. The Stub Roller was designed by the Caster Concepts Engineering team to drop in without any modification. Caster Concepts used its 95A polyurethane to improve wear and life of the drive surface.

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Customer: Advanced Ground Systems Engineering Application: Jet Engine Transport Dolly Issue: Fragile Payload. Next Generation Engines were larger and heavier. This increase in size and load was causing competitor's product to experience swivel bearing failure. Warranty claims were very expensive as the engine dollies were in service around the world. Replacement casters had to be flown to the site to get the equipment back into service. The failure was causing the AGSE customer to lose confidence in the product. Solution: Caster Concepts sales and engineering team designed a 91 series kingpinless style, spring loaded caster that would survive the increased impact loads on the caster due to the heavier loads. Warranty claims have been eliminated and customer satisfaction has been restored.

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Customer: Conveyor Manufacturer Application: Conveyor System Issue: The manufacturer needed a domestic supplier to provide complete subassemblies. The customer was previously purchasing the product overseas and it was both expensive and time consuming for the product to by flown from Europe Solution: Caster Concepts was able to design, manufacture and deliver these products in less than 3 weeks. This saved the manufacturer time and money.

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SPD08051601/ 02

Customer: Material Handling Manufacturing Application: Transportation of Railroad Cars through the manufacturing process Issue: Extreme Loads each wheel had to carry 17,500 pounds and roll freely. Solution: Caster Concepts sales and engineering team worked with the customer to design and build solid steel single flange wheels on a stub axle. The axle /wheel assembly was mounted between pillow blocks for increased bearing capacity and alignment. One set of wheels was driven to power the rail car through the manufacturing process.

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Powder Coated Caster

Customer: Aircraft Component Manufacturer Application: Tow Tractors Issue: The current casters were very expensive and were not holding up to the application and environment at the plant. Solution: Caster Concepts spent time in the facility to fully understand the problem. By working in the plant CCI was able to understand how the caster was used and what the performance standards were required. With the help of the CCI engineering team the customer was presented with a product specially designed for them to meet all their needs. The product has been used at the facility for 4 months and the company is beginning to standardize the Caster Concept products for all their future caster needs.

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SPD091102

Customer: Design Implementer Application: Automotive assembly conveyor, power drive rollers. Convey the automobiles through the weld and final assembly processes. Issue: Source of supply is in Italy. Lead-time and ocean freight would not allow the customer to meet their customers' delivery expectations. Solution: Caster Concepts was approached to manufacture rollers within 3 weeks, to meet customer expectations. CCI engineering and manufacturing teams pulled together designed and manufactured the rollers on time so that they could be installed during plant shutdown, lessening the impact of the changeover.

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T/R Compound Wheel

Customer: Tire Manufacturer Application: Industrial Carts Issue: Build up of Green (raw) rubber in the manufacturing process Solution: Using a T/R compound wheel the pickup of debris on the wheel was significantly lessened The wheels previously placed on the carts were picking up debris making the tires out of round as well making the carts hard to push. With the use of the T/R compound wheel the debris picked up by the wheel was significantly decreased making the cart easier to push and keeping the wheel in round.

Before with Green tire build up

After 9 months with a T/R compound wheel

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Caster Concepts, Inc.

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Laser Formed Casters

Customer: Modular Home Manufacturer Application: Moving parts through the manufacturing process Issue: The casters were bending and the legs were snapping off Solution: Caster Concepts developed and built a custom caster with wider one piece legs and a heavier cross section. Caster Concepts was given the challenge of designing a caster that would be stronger and more robust while fitting into the existing operating space. The pictures show the details of the 2 piece laser cut and formed leg design. With the expertise of Fabricating Concepts and Conceptual Innovations Engineering, Caster Concepts was able to deliver a product that met the customers’ needs completely.

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Engine Cart Side and End Plates

Customer: Aerospace Manufacturer Application: Laser cut company name on to aerospace engine carrying carts Issue: The aerospace company wanted to have their name and serial number placed directly on the carts without the use of removable stickers or paint. Solution: Fabricating Concepts, a division of Caster Concepts was able to laser cut 36 individually unique plates for each engine cart with the company name as well as serial number on each side plate.

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Hanging Orbs

Customer: Sculptor of constructive geometric forms Application: To be put on display in a college science building Issue: The sculptor required pieces of powder coated aluminum to be cut in various shapes ranging from 42 to 48 inches in diameter that could be put together precisely to create the series of 9 orbs. Solution: Fabricating Concepts was able to cut each of the parts using their laser. Each piece was precisely cut and all 9 orbs turned out just as the sculptor had envisioned

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Drive Simulator Chassis Customer: Graphic Simulation and Modeling Application: The customer state of the art driving simulators for universities, government institutions and commercial entities. These driving simulators help research study driving behavior and teach driving techniques. Issue: The customer wanted to attack new a market that required a modular, lower cost machine. They needed assistance in designing and manufacturing a new simulator chassis. Solution: Fabricating Concepts engineered a low cost, lightweight chassis that was easily transportable. The chassis could be broken down into multiple modules, transported in a small SUV or van and reassembled in a few hours by a two person team. The chassis was designed entirely out of laser cut and formed components and then assembled either by welding or with screw fasteners.

Conceptual Innovations

Engineering

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CasterShoX™ Technology

Customer: Wide Variety Application: CasterShoX’s™, a patented ultra-compact shock absorption technologies, is used to reduce noise, attenuation shocks and provide suspension functionality directly from the caster product. Issue: Problems created by everyday casters include excessive noise and vibrations. Solution: CasterShoX™ casters, which were created to combat the pesky problems of everyday casters, have been tested in an industrial setting and can reduce noise by as much as 15dbA. CasterShoX™ casters are identical to conventional casters in appearance, shape, and size. The two standard sizes CasterShoX™ casters are available in include 6x2 and 8x2. CasterShoX™ casters are smaller, more economical and better performing because they inherently add damping to ensure stability.

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Navy Dynamometer

Customer: Military Application: Custom Test Equipment used to evaluate performance of a 500HP electric motor Issue: Design and build a 500 horsepower water brake dynamometer to allow the customer to test various motor control schemes and hardware. The test dynamometer was required to be housed in a mobile shipping container Solution: Caster Concepts engineering team developed a custom test machine which incorporated an off the shelf water brake dynamometer. CCI engineers developed a custom drive train to allow the high torque/low speed test motor to interface with the high speed dynamometer. CCI engineers also wrote custom software to be able to control the dynamometer torque output. Software continuously measured torque from the equipment and fed back the data to the single PC base control system. To close the loop, the PC based control system would automatically regulate the flow rate into the water brake dynamometer resulting in changes in torque output. Software also monitored water temperature and also rotational speed.

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Dynamic Wheel Endurance Test Machine

Customer: Caster Concepts Application: Caster Concepts engineers have developed a state of the art, fully automated testing machine to simulate real world use of their products in a laboratory setting. Issue: Caster Concepts needed a sophisticated and automated means of conducting failure analysis for their heavy duty industrial casters. Solution: The Dynamic Wheel Endurance Test Machine (DWETM) is fully computer controlled (PC Based) and able to run 24/7 entirely unattended. It is able to automatically and programmatically change its testing conditions, the load, the speed and the test duration. The DWETM is able to simulate static and dynamic loads up to 10,000lbs and speeds up to 20 MPH. The DWETM is capable of automatically stopping the testing session when it senses any one of the various failure conditions. The DWETM is instrumented with a force load cell, to measure load on the test product, a torque and speed sensor, to measure the speed of the wheel and the torque being exerted onto the test wheel, an infrared temperature sensor, to measure wheel temperature, and an accelerometer to measure machine vibration. All data is fed directly into the PC based controller and can be reviewed and analyzed using custom written software programmed in LabView.

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Fuel Cell Shock Absorber

Customer: Fuel Cell Manufacturer Application: The customer designs and manufactures state of the art ceramic fuel cell products for a host of military, aerospace and industrial applications. Issue: The problem with ceramic fuel cells is that they tend to be fairly fragile. In order to ruggedize their product, the customer asked Fabricating Concepts to design and manufacture an ultra light weight compact shock absorber that would allow their product to withstand multiple drops from elevations of up to 10 ft. Solution: The engineering team developed a 3 axis suspension system using a flexural spring design similar to our patented CasterShoX products. The flexural design allows the spring to be ultra lightweight and compact. Tests show that it reduces G force shock loading by a factor of 20.

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Grippers

Customer: Automotive Assembly Plant Application: The customer supplies numerous automotive sub-assemblies to other automotive assembly plants. The customer wanted an engineering and manufacturing company to re-design a set of grippers that were currently being used in an automated shaft grinding operation. Issue: Current grippers were unreliable. They required constant maintenance and required significant time to setup and zero. Solution: Conceptual Innovations provided mechanical schematics of the current grippers and the grinding cell. Conceptual Innovations engineers redesigned the gripper assembly to be cost effective and easily maintained. Features were implemented that allowed setup to be done in a few minutes vs. the hours it used to require. Conceptual Innovations Engineering manufactured all machined components including all gripper fingers and mounting plates. Conceptual Innovations engineering performed all assembly and testing and delivered the gripper assembly on time and on schedule.

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Bungee Cord Roll Blank

Customer: Personal Interest Application: The two plates made by CCI face each other and a bungee cord is wrapped around the middle. Issue: The customer was using a tin alloy which was rusting. Solution: Caster Concepts was able to make the part out of hard polyurethane which will not rust and can withstand wet environments.

Magliner Wheels

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Polyurethane Sprockets

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Customer: Hand Truck Producer Application: This wheel, which was a new development, is being used on a powered hand truck to deliver vending products. Issue: The customer wanted to improve the appearance of the threads and durability of the product Solution: CCI engineers were able to develop a thread using polyurethane. The customer chose Caster Concepts for this project because CCI could be more competitive on the tooling by using the urethane process rather than if the customer had gone with a rubber molding process. Caster Concepts offered engineering development and managed the supply chain to hand them a complete wheel assembly. As part of the job, CCI engineered and manufactured their own sand cast tooling and polyurethane molds. CCI developed a custom polyurethane spin molding process to ensure that the wheels were processed with good quality.

Hand Truck Wheels

Caster Concepts, Inc.

Nissan Clamp Plate

Customer: Automotive Manufacturer Application: Clamp for lift assist to grab and move painted car doors Issue: A clamp plate was needed that could move a car door without scratching the painted surface Solution: Caster Concepts employees were able to engineer and coat the clamp plate with an 85A compound.

Polyurethane Sprockets Customer: Distributor Application: This sprocket is designed to be used on a conveyer in a women’s clothing distribution center. Issue: The sprockets were failing too quickly. Solution: CCI employees were able to coat the sprockets in hard polyurethane allowing the part to endure more physical use. The sprockets that the OEM was using were breaking teeth off. CCI, however, was able to adjust the polymer to make a more durable product thus eliminating the breakage the customer had been experiencing. Departments such as Reaction Industries, Engineering, and Machining collaborated to make this part possible for the distributor.

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Original Faulty Sprocket

Sprocket Engineered By CCI

Door Carrier Customer: Automotive OEM Application: This part was used to transport painted doors in an automobile factory. Issue: The customer has difficulty finding consistent quality of the polyurethane and shape of the part. If the poly part doesn't fit properly, painted surfaces of the car can be scratched leading to added cost in rework and repair. Solution: Caster Concepts was able to work with the customer to develop a mold that produces consistent parts in the shape that best fit their needs. CCI used Reaction Industries and its engineering capabilities to meet the customer's needs. By working closely with the customer CCI was able to understand their goals and eliminate the stress related to this product.

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Trailer Hitch

Customer: Cart Manufacturer Application: To be use as a trailer tongue Issue: The customer was looking for a durable material in order to increase the life of the tongue. The pin that goes through the tongue wears the polyurethane out quickly, making the connection of the trailers generate noise Solution: By using a special polyurethane compound with high cut/tear resistance, CCI was able to increase the life of the product.

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Hummer Wheel

Customer: Mobility products developer Application: To be used as an airless tire Issue: The customer was looking to create a prototype of the airless tire and was unable to find the proper material to fill the mold Solution: Reaction Industries was able to fine tune the creation process as well as figure out how the material should be processed

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Racing Simulator Parts

Customer: Computer Racing Simulator Manufacturer Application: These parts were specially designed and made to be part of new driving simulator Issue: The Company needed these parts to be functional and look flawless because they would be placed on the outside of the driving simulator. Solution: The Machine Center was able to deliver flawless parts made of the desired aluminum product because of the special machining expertise available within the organization.

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Dip Stick and Hub

Customer: Drivetrain Manufacturer Application: Motorcycle oil dip stick and clutch hub Issue: The customer was looking for a creative and less expensive way to produce both of these parts Solution: Triple E was able to beat out the competition and offer the product the customer was looking for at a lower price because of the use of different machining practices.

Motorcycle oil dip stick

Motorcycle Clutch Hub

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Center Slider and Slider Barrel

Customer: Laser Fabricating Company Application: Slider valve assembly for post pounder Issue: The customer was experiencing very long delivery times from their previous supplier and need the part quickly. Solution: Triple E worked closely with the engineering team at Caster Concepts to redesign the slider valve. With the redesign Triple E was able to produce the product very quickly and expedite the order.

Shift Drum

Customer: Drivetrain Manufacturer Application: Shift drum to be used in the assembly of American motorcycle transmissions Issue: The customer needed a specially machined shift drum to complete the assembly of a particular type of motorcycle transmission. The part was required to be machined at tight tolerances. Solution: The Machine Center was able to complete this project as per the customers’ needs and standards using special 3-D programming.

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Sleeve Broach

Customer: Automotive Supplier Application: Automotive Assembly Issue: The customer was unable to find a company that could produce this product in a cost effective form. Solution: Triple E was able to compete and win in the market because of their broach machine. With a 5 second cycle time Triple E was able produce this product for pennies on the dollar when compared to competitors. Up to 30,000 sleeve broaches can be made in a week.

Sleeve Broach

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Telescoping Steering Wheel Mechanism

Customer: Manufacturer of Automotive and Truck Steering Columns and Shifters Application: Telescoping steering wheel for large trucks Issue: The original part needed to be able to slide back and forth freely while handing more torque than it previously was able to handle. Solution: Triple E was able to develop a robust product which could handle more torque than previously.

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Ertalyte Wheel

Customer: Machine Shop Application: Conveyors Issue: The customer needed unique material machined at high tolerances at a reasonable price Solution: The Machine Center and Triple E worked together to complete this project. The Machine Center completed the machining of the 16,500 wheels and well and inserted the bearings and the axles. Triple E machined the axles to be place in the wheel. The wheels were then placed in a conveyor system and sent to the end user.

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HTD Sprocket

Customer: Automotive Assembly Line Application: Part of the drive mechanism Issue: The customer was looking for a product of equal or better quality at a lower price point. Solution: Triple E was able to not only engineer the HTD Sprocket, but they were able to produce it at a lower cost as well.

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Customer Testimonials

July 12th, 2010 Mr. Zach Norkey,

First on behalf of everyone involved with Lifline we would like to thank you for your continued business relationship with us.

As you know we manufacture specialized equipment that requires the casters provided by Caster Concepts. The casters you provide have made a significant improvement with our equipment, our clients have made very positive remarks since we switched to your product.

You have helped tremendously each time we have requested the casters and the delivery time has been cut in half. Prior to obtaining the casters from you we had issues with the other supplier on delivery times, product not in stock and other issues that caused delays with our equipment.

These issues have been eliminated even to the point when we call and request a rush item.

Again I want to thank you for all the help your company has provided to Lifline.

Theodore Wilkinson

Technical designer

Lifline LLC

Lifline

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DD7-100 Shift Drum

Rico Equipment

July 27th, 2010 Brief description of the Application:

Self guided vehicle that will transport 65,000 lb max jet engines. Two casters are needed, one in opposite corners and drive units in the other corners. The unit will travel north until it is located under the jet engine rack. LVDT cylinders lift the rack to required height. The vehicle will travel east until out of storage area and then maneuver along to its destination.

Brief description of how Caster Concepts worked with you:

[Caster Concepts] helped me decide the proper caster to utilize and gave me an understanding of how the caster is made as well as confidence to purchase. I was able to get a 3D model to make sure that the caster will fit and the turning radius cleared.

What did you think of the service provided?

The service was exceptional. [Caster Concepts] answered all my questions in the same day that I asked. They were especially great to work with on modifications.

Product, your thoughts:

The casters are impressively large. The welds are clean and the unit overall looks heavy duty. Although, we have not installed the casters yet, the swivel bearing seams tight and smooth to turn. That’s very important in order to handle the harsh conditions that it will undergo.

~Rod Loveday

16000 East Michigan Avenue

Albion, Michigan, 49224 www.casterconcepts.com

E: adobbins@casterconcepts.com

P: 517-629-8838