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Author Archives: Sarah Bunales

  1. Equipment Loading and Transport Machine (Rotating Lift Cart)

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    Customer: Large manufacturer of decentralized power stations
    Industry: Energy

    Equipment Loading and Transport Machine (Rotating Lift Cart)

    Sigma designs and builds custom transport and loading/unloading machines for a large manufacturer of decentralized power stations

    The “Rotating Lift Cart” designed by Sigma Design for a large manufacturer of decentralized power stations was created to assist fabricators and assembly technicians with moving their heavy test equipment from the final stages of the assembly line to the testing area, as well as assist with the loading and unloading of the equipment. The Rotating Lift Cart features an integrated scissor lift with a rotating table, allowing the equipment to be loaded from either side of the machine at heights from 12” to 30”.

    The cart is driven using a Master Mover Electric Tugger via a custom coupling between the tiller and the cart. To help the operators load and unload the equipment, a DC Gearmotor-driven lead screw linear actuator is used to either pull or push the 800+ lb. equipment into or out of the testing enclosure. For the cart to be fully utilized when it is separated from the assembly line, a dual power solution was devised. When the cart is used on the assembly line, it can be powered from an AC drop at that station. When the cart is moving from station to station or moving away from the assembly line, the cart can be powered from the DC battery inside the Master Mover Tugger. This flexibility allows the scissor lift and actuator to always be functional, giving the operators more assistance in all parts of the factory.

    Services Performed: 

    Concept development, testing protocol, controls, sensors, electronics, complete fabrication including all controls, machining, validation, and testing.

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  2. Mattress ASTM Testing Machines

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    Customer: SGS Govmark
    Industry: Industrial Testing and Certification

    Mattress ASTM Testing Machines

    Sigma designs two machines for SGS Govmark to evaluate mattresses to ASTM F1566-14 Specifications 

    The Durability Tester and the Cornell/Firmness tester are two standalone machines that were developed to test mattresses according to the procedures defined in the ASTM F1566-14 Specification. 

    The Durability Tester is used to test mattresses according to Section 7 of the specification and can test mattresses from twin size to queen size. The machine moves a 240 lb. roller back and forth across the mattress to simulate years of use. The roller is driven back and forth across the mattress via a servo driven belt system and once it starts it can run 100,000 cycle tests automatically without operator intervention or supervision. It features safety mat system to detect if any objects or person gets too close to the machine while operating and automatically stop all motion. The Cornell/Firmness Tester is used to test the mattresses according to Sections 6 & 9 of the specification. 

    The Cornell Tester uses a servo driven linear actuator with a two- lobe platen to continuously plunge into the mattress at 100 strokes per minute. A load cell mounted between the actuator and the platen is used to measure reactionary forces and determine how deep into the mattress to plunge. The machine then automatically stops at defined cycle counts and performs measurements on the reactionary forces of the mattress at set depths. Before and after a Durability Test or Cornell Test, a firmness test is run to determine the mattresses firmness in its “new & unused” state. The Firmness Test uses the same servo-driven linear actuator with a flat platen to plunge into the mattress at a rate of 10 inches per minute. The results during the test and changes between the before and after tests are then summarized in a table on the HMI as well as graphically for the operator and manufacturer to see the change in mattress properties over the duration of the test. 

    Services Performed: 

    Concept development, testing protocol, controls, sensors, electronics, complete fabrication including all controls, PLC/HMI, machining, validation, and testing.

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