Projects
This bespoke system measures multiple aspects of 400-series diesel engines, including head gasket thickness and fuel injection pump shim thickness.
• High-Precision Technology: Features a Micro Epsilon 2060 measurement sensor mounted on a 6-axis robotic arm for accurate, automated measurement.
• Flexible Production: Handles any engine variant in any order — no tooling changes required.
• Data Integration: Results are stored in a local SQL server database and linked to the factory MES system for real-time traceability.
The system is designed for accuracy, efficiency, and reliability, helping manufacturers maintain strict quality standards
This retro-fitted automated assembly solution was installed on an existing production line to assemble two precision components into eight small sub-assemblies within a 14-second cycle time.
• Bespoke Engineering: Developed to integrate seamlessly into the customer’s live production line.
• Advanced Manufacturing: Used complex material forming and 3D printing processes to overcome production challenges.
This fully automated system measures the diameter and straightness of large defence components with micron-level precision.
• Manual Loading, Automated Analysis: Ensures operator safety while maintaining accuracy.
• High Data Output: Generates over 1,000,000 data points per component for comprehensive evaluation and full quality assurance.
• Efficient Cycle Time: Typical cycle is 2–5 minutes, plus loading and unloading, making it ideal for production environments.
• Optional Vision Integration: Adds visual inspection of screw patterns and correct assembly verification.
By combining automation, precision measurement, and traceable data logging, this system meets the demanding standards of defence manufacturing while ensuring speed, safety, and repeatable accuracy.
This advanced machine assembles 2mm NCV guide and pin-matched pairs, then performs a full sequence of assembly, measurement, and testing to ensure precision and reliability.
• Automated Handling: A robotic system moves components through each stage — from the input pallet, across all intermediate stations, and back to the output pallet.
• Comprehensive Testing: Includes lift measurement, two seat pressure tests, and one flow test, ensuring accuracy at every stage.
• Software Flexibility: Stores, changes, and controls multiple variants of test plans. Functions such as assembly, lift measurement, or individual hydraulic tests can be turned off or adapted within the software.
• Hydraulic Leak Testing: The system hydraulically pressurises each component to check the interface between a retained ball and the machined seat. Leakage is measured as pressure decay over time — with configurable software settings (e.g. a 5-second stabilisation period followed by a 5-second decay measurement).
This semi-automatic assembly aid was developed to support operators during the installation of critical components, ensuring accuracy, repeatability, and compliance with defence standards.
• Operator Support: A manually loaded fixture assists the operator in positioning and securing the correct number of screws.
• Precision Control: Each screw is tightened to its specified torque and angular distance, guaranteeing consistent assembly quality.
• Integrated Monitoring: A torque screwdriver system is built into the existing fixture and monitored via a bespoke interface.
• Full Traceability: The interface records the number of rotations, torque applied, and screw presentation to ensure every fastening meets specification.
This solution provides a reliable, efficient method of maintaining assembly integrity while reducing the risk of operator error
This bespoke test rig was designed to support new product development of dynamic variable flow control valves.
• Versatile Testing: Handles valve sizes from ½ inch to 4 inches, supporting a wide range of product applications.
• High Capacity: Delivers flow rates up to 30 litres per second at pressures of up to 6 bar.
• Data-Driven Performance: Features fully integrated data logging and test reporting for traceable quality assurance.
• Flexible Operation: Provides total software flexibility, allowing variability in test parameters with both manual and automatic control, giving engineers maximum adaptability during development.