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A series of service cabinets and other equipment were targeted for review when hoisted overhead. The various units were measured in the field and modeled in PTC’s Wildfire 5.0. Lifting and loading conditions were simulated using PTC’s Mechanica FEA software. Reports were prepared for each unit identifying acceptable performance, failing performance and possible solutions for increasing performance to meet requirements. Failing units were reviewed for potential design solutions for improving each to meet safety requirements.
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Background:

Customer had limited production circuit boards which were being assembled and soldered free hand or with crude clamping and holding mock ups. Results were poor quality and low production output.

Product

Flip Jigs and Holding Fixtures to be used for Circuit Board Solder & Assembly

Scope

Enser was tasked with developing tooling and fixtures that required multiple wires and solder connections be made on a single board without interfering with each other during the process. Fixture had to limit the number of tooling moves per process to reduce operator fatigue. Operation might be performed by medium skill level personnel so simplicity of operation had to be met.  Minimum production quantities must be maintained without need to stop and clean solder splash from fixture.

Results

Enser designed and built a series of custom flip jigs that allowed all soldering and wired connections be completed in a single fixture. Product assembly defects were reduced by 80% and production was increase by 150%.
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Background:
Enser was tasked with design and build a fixture to lift and turn down a fully assembled stator housing.

Product

250 TON IMG_20140611_082657754Turn Down Fixture

Scope

This fixture was designed to lift and turn down a fully assembled stator housing. The total weight of the fixture and stator was 250 metric tons. The fixture was designed using lightweight high strength material in some areas to cut weight as the crane capacity in the area was at its limit. The fixture would be assembled piece by piece onto the stator. The stator would be lifted and then turned 90 degrees using the auxiliary crane hook. The stator would then be placed on a set of power rolls in the horizontal position. At this point the fixture would be disassembled in reverse order and returned to the storage rack.

Result

Enser completed the task in the scheduled time frame and the fixture was a success.
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Background:

Design and Build of a table top Nitrogen bottle purging and capping system.

Product

Nitrogen Purging and Capping System

Scope

Enser worked with the company to design and build this custom transportable bottle machine. The system contains a linear slide for bottle transport from station to station and a linear cylinder to engage N2 and/or capper. Controls with a touch screen for adjustments and system monitoring.

Result

  • Cycle time improved by 35%.
  • Non conformance reduced 50%.
  • Labor reduced 23%.
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Background:
Enser was tasked with the engineering, design and build including FE Analysis reports validating performance for safe functional operation, overhead lifting, and transportation.

Product:

35 Ton Rotor Transport Skid

Scope:

This transport skid was designed and then validated  for performance of safe functional operation, overhead lifting, and transportation.  Lifting performance included lifting an entire transport skid and rotor system.  Lift testing of the unit was completed in its operating conditions at 125% capacity.
Validation Criteria for Acceptable Overhead Lifting Performance while loaded: Compliance to ASME BTH-1, 2008 Validation Criteria for Acceptable Transportation Performance: Compliance to conditions defined by Federal Motor Carrier Safety Administration (FMCSA), Cargo Securement Rules:
  •  0.8 g negative acceleration in the forward direction
  •  0.5 g acceleration in the rearward direction
  •  0.5 g acceleration in a lateral direction
  •  0.5 g acceleration in the vertical upward direction

 

Result

Enser completed the task in 16 weeks and the skid is performing as required.
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 Background:
Enser was tasked with development of dynamic systems and controls for an advanced energy system that was incorporated into a non-invasive therapy for chronic psychiatric and neurological disorders.

Product

Neurostar TMS Therapy System for non-invasive therapeutic treatment of depression.
Neurostar TMS Therapy SystemNeurostar TMS Therapy System
 

Scope

The technology used in the concept was converted to a detailed engineering design package; a working model was built for testing and design verification. The design consisted of a proprietary system to generate high intensity magnetic pulses capable of focused brain stimulation, and a head frame necessary to administer the therapy. The working model was subjected to a series of tests to simulate its operational environment. The system testing included a control console, and proprietary Flux Magnification TM technology generated powerful focused magnetic pulses at high frequency for penetration of the skull and stimulation of the left prefrontal cortex. The centerpiece was a specially engineered and fabricated magnet/pulse therapy coil, precisely positioned against the patient’s head. It then administered targeted magnetic pulses stimulating brain cells and alleviating the symptoms of depression. The device is ergonomically sleek and aesthetically pleasing and a completely self contained unit.

Result

Enser performed the manufacturing and performance monitoring of 30 test units providing project management, configuration management, reliability analysis, engineering retrofit improvements and quality assurance. Enser also maintained a complete FDA Quality Control documentation package for manufacture and maintenance of 30 units deployed for FDA clinical trials. http://www.neurostar.com
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