Below are a few design projects WDSI was involved with.

AGFM Insert Checker
agfm checked d01.jpg (245925 bytes)agfm checked d03.jpg (239923 bytes)agfm_checker_r02.jpg (169113 bytes)agfm_checker_r01.jpg (169773 bytes) WDSI Involvement:
  • Conceptual Sketches
  • Design
  • Complete Drawing Package
  • Parts Ordering
  • Assembly Management
CAD Software Used:  Inventor
Description:  Fixture designed to hold an AGFM cutter head in a vertical position to ease replacement of cutter insert.  The cutter head is bolted to the fixture and rotated by a stepper motor using a hand wheel control.  After all the cutter teeth have been replaced, the gage arm is placed into position.  A dial indicator is used to check the height difference from tooth to tooth within .0001 inches.

Robotic Material Handling Arm

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 WDSI Involvement:
  • Conceptual Sketches
  • Design
  • Complete Drawing Package
  • Parts Ordering
  • Assembly Management
CAD Software Used:  Pro-Engineer
Description:  Conceptual sketches of a complete material handling system were developed to manipulate rubber-roofing materials.  System was designed to eliminate injuries related to lifting of heavy rubber roofing materials.  From the sketches the design and detailing of robotic arm was competed, parts ordered and assembly managed.  We worked close with the material manufacture and electrical engineers to verify that all aspects of the project had been considered.

Matrix Band Machine

WDSI Involvement:
  • Design
  • Complete Drawing Package
CAD Software Used:  Pro-Engineer
Description:  High-speed machine for dental industry that makes the matrix band that is wrapped around your tooth while being filled.  3" wide stainless steel is feed through a progressive die at the rear of the machine.  The part is then transferred to the front units were a large conical loop is made, a lock loop is fastened to it to hold the shape, and 6 tight winds are placed at the other end of the part.  The finished part is transferred to a vision inspection station where it is determined a "good" or "bad" part.  A part is made every 3 seconds.  The machine was designed to make 4 different size matrix bands with minimum changeover. 

Arial Lift Platform

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 WDSI Involvement:
  • Design
  • Complete Drawing Package
  • Parts Ordering
  • Assembly Management
CAD Software Used:  Pro-Engineer
Description:  New aerial lift platform design with automatic assist lift up front gate.  The customer came to us with the concept sketch.  WDSI developed the complete design / detail package then managed all aspects of the build for the first prototype.

Cylinder Assembly and Test Station

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WDSI Involvement:
  • Conceptual Sketches
  • Design
  • Complete Drawing Package
  • Parts Ordering
  • Assembly Management
CAD Software Used:  Pro-Engineer
Description:  Machine designed to build, pressure test, cycle and clean hydraulic cylinders.  The piston is assembled onto the rod on the center section of the table.  The rod is assembled into the cylinder on either side of the table.  The one side of the table will be in the up position doing the pressure checks and cleaning cycles while another cylinder is being built on the opposite side of the table.  The station is designed to handle a wide range of cylinder types and lengths with minimum tooling changeover (no tools required).

Door Router Fixture

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WDSI Involvement:
  • Design
  • Complete Drawing Package
  • Parts Ordering
  • Assembly Management
CAD Software Used:  Pro-Engineer
Description:  Large door and window manufacture requested the design and build of a fixture that would allow them to route hinge mortises consistently.  The fixture had to be capable of accepting multiple heights, widths and thickness along with both left and right hand doors. WDSI designed and detailed a complete package along with ordering parts and managing the assembly.  The fixture had pneumatic clamping and a no tools required changeover.

Boom Tack Welding Fixture

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WDSI Involvement:
  • Design
  • Complete Drawing Package
  • Parts Ordering
  • Assembly Management
CAD Software Used:  Pro-Engineer
Description:  Tack welding fixture designed to handle 3 different booms with no tooling changeover.  Subassemblies are positioned and clamped on the fixture then a welder tacks components in place.  After fixture was assembled at our facility a complete laser inspection is done to certify critical positions. The fixture was designed to hold the locating items within +/-.006".

Hydraulic Clamping Boom Tack Welding Fixture

boom fixture 2 d01.jpg (328957 bytes)boom fixture 2 d02.jpg (311365 bytes)

WDSI Involvement:
  • Design
  • Complete Drawing Package
  • Parts Ordering
  • Assembly Management
CAD Software Used:  Pro-Engineer
Description:  Tack welding fixture designed to handle 2 different booms with no tooling changeover.  Subassemblies are positioned and clamped on the fixture then a welder tacks components in place.  After fixture was assembled at our facility a complete laser inspection is done to certify critical positions. Due to the extreme size and weight of the boom parts, hydraulic cylinders were used to push and clamp boom and loose pieces together.  The fixture was designed to hold the locating items within +/-.006".

Frame Tack Welding Fixture

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WDSI Involvement:
  • Design
  • Complete Drawing Package
  • Parts Ordering
  • Assembly Management
CAD Software Used:  Pro-Engineer
Description:  Tack welding fixture designed to handle 3 different frames with no tooling changeover.  Individual plates are positioned and clamped on the fixture then a welder tacks components in place.  After fixture was assembled at our facility a complete laser inspection is done to certify critical positions. The fixture was designed to hold the locating items within +/-.006".

Lay-on Tack Welding Fixture

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WDSI Involvement:
  • Design
  • Complete Drawing Package
  • Parts Ordering
  • Assembly Management
CAD Software Used:  Pro-Engineer
Description:  Tack welding fixture designed to handle 2 different booms with no tooling changeover.  The fixture locates the nose weldment and the cylinder attach plates relative to the end of the boom within +/-.006".  After fixture was assembled at our facility a complete laser inspection is done to certify critical positions. no tooling change-over.  The fixture locates the nose weldment and the cylinder attach plates relative to the end of the boom within +/-.006".

Rollover Welding Fixture

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WDSI Involvement:
  • Design
  • Complete Drawing Package
  • Parts Ordering
  • Assembly Management
CAD Software Used:  Pro-Engineer
Description:  Welding fixture designed to handle 2 different axle boxes (about 1600 lbs each) with no tooling changeover.  The fixture holds the axle box off the floor for complete welding access.  A hand wheel attached to a worm gear is used to rotate the axle box to any angle for welding.  The rotation can be locked in at 90-degree increments.

Auxiliary Rescue Units

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foster r01.jpg (41939 bytes)foster r02.jpg (40865 bytes)foster r03.jpg (36368 bytes)

WDSI Involvement:
  • Design
  • Complete Drawing Package
  • Parts Ordering Support
  • Manufacturing Management Support
  • Assembly Management Support
CAD Software Used:  Inventor
Description:  Primary design source for Foster Rescue Products.  WDSI began work with Foster to reverse engineer their first emergency rescue unit.  Since the initial project we have played a part in the development of more than 6 new models and multiple versions of each model.  This is an ongoing project due to the highly specific and constantly changing requirements of each unit.

Dump Trailers

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WDSI Involvement:
  • Reverse Engineering
  • Product Cost Optimization
  • Design
  • Complete Drawing Package
CAD Software Used:  Inventor
Description:  WDSI has been involved with several trailer manufactures.  We have completed reverse engineering and new design/detail projects on single and tandem axial trailers that have either solid or dump beds.  Also we have done consulting along with product cost analyzes and fixture design.

Landis Ballscrew Retro-Fit for Wheel Feed

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WDSI Involvement:
  • Design
  • Complete Drawing Package
  • Parts Ordering
  • Assembly Management
CAD Software Used:  Pro-Engineer
Description:  Retrofit and retool packages for the machine tool industry is a specialty of ours.  We have done designs to fit ballscrews and CNC control dressers into older vintage machines. 

Dresser Retro-Fit for Grinding Wheel

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WDSI Involvement:
  • Design
  • Complete Drawing Package
  • Parts Ordering
  • Assembly Management
CAD Software Used:  Pro-Engineer
Description:  Retrofit and retool packages for the machine tool industry is a specialty of ours.  We have done designs to fit ballscrews and CNC control dressers into older vintage machines. 

Excello Retool - Crankshaft Radial Orientation Hole

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WDSI Involvement:
  • Design
  • Complete Drawing Package
  • Parts Ordering
  • Assembly Management
CAD Software Used:  Pro-Engineer
Description:  Retrofit and retool packages for the machine tool industry is a specialty of ours.  We have years of experience in developing tooling for new equipment and retooling used equipment for new processes or OEM parts.

Rack and Pinion Drive Retro-Fit for a Boom Welder

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WDSI Involvement:
  • Design
  • Complete Drawing Package
  • Parts Ordering
  • Assembly Management
CAD Software Used:  Pro-Engineer
Description:  A hydraulic cylinder originally drove the boom welder table.  We removed the cylinder and replaced it with a rack and pinion servo drive system.  This allowed the speed of the welder table to be controlled and reduced the jerkiness caused by the inconsistent pressure in the cylinder.

Rack and Pinion Drive Retro-Fit for a Boom Welder

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WDSI Involvement:
  • Design
  • Complete Drawing Package
  • Parts Ordering
  • Assembly Management
CAD Software Used:  Pro-Engineer
Description:  A push pull chain originally drove the boom welder gantry.  We removed the push pull chain and replaced it with a rack and pinion servo drive system.  A servo drive system was mounted on each side of the gantry.  This allowed the speed of the welder gantry to be controlled and reduced the jerkiness caused by the push pull chain.

Manure Solid and Liquid Separator

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WDSI Involvement:
  • Reverse Engineered
  • Re-Designed Some Items
  • Complete Drawing Package
CAD Software Used:  AutoCAD
Description:  The manure solid liquid separator is used to manage manure problems, such as odor, run-off, soil compaction, and environmental liability.  We were able to work with the OEM to get their ideas into a drawing package ready for manufacturing.

Machine Mist Enclosure

WDSI Involvement:
  • Design
  • Complete Drawing Package
CAD Software Used:  AutoCAD and Helix
Description:  WDSI has designed complete watertight enclosures for the machine tool industry.  We have worked closely with sheet metal manufactures to optimize the design with manufacturing as a primary concern.  Enclosures typically have sliding or hinged front/loader doors with safety interlocks.  Also lifts off panels are strategically placed to allow easy access for servicing the machines.

Hydraulic Cylinder

WDSI Involvement:
  • Design
  • Complete Drawing Package
CAD Software Used:  AutoCAD
Description:  Cylinder design and reverse engineering for manufacturers of hydraulic cylinders used in products ranging from hydraulic dump beds and trailers to cranes and aerial work platforms. We have had involvement with Single Acting, Double Acting, Telescopic, Ram and Custom Designed Cylinders.

Machine Tooling

WDSI Involvement:
  • Design
  • Complete Drawing Package
CAD Software Used:  AutoCAD
Description:  Retrofit and retool packages for the machine tool industry is a specialty of ours.  We have years of experience in developing tooling for new equipment and retooling used equipment for new processes or OEM parts.

Machine Loader

WDSI Involvement:
  • Design
  • Complete Drawing Package
CAD Software Used:  AutoCAD
Description:  Retrofit and retool packages for the machine tool industry is a specialty of ours.  We have years of experience in developing tooling for new equipment and retooling used equipment for new processes or OEM parts.

Hydraulic and Pneumatic Diagrams

WDSI Involvement:
  • Design
  • Complete Drawing Package
CAD Software Used:  AutoCAD and Pro-Engineer
Description:  Design of new equipment or upgrading of vintage machinery often involves incorporating fluid control.  We are capable of the design and documenting of hydraulic and pneumatic systems.  We also have very close ties to an electrical control company who we often call upon for support.

Design Proposal and Brochure Drawings

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 WDSI Involvement:
  • 3-D Modeling
  • File Conversion
CAD Software Used:  Pro-Engineer and Inventor
Description:  On several occasions customers have approached us to assist in the creation of 3D, isometric and exploded views to be used for sales literature and design proposals.  Through the use of our 3D software we have constructed geometry from drawings or sketches and created the views required then exported the information to a user-friendly format.

 

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