Posted by & filed under Design.

If you think simulations have little value when it comes to real-world applications, you’ve probably forgotten your driver’s education course. When learning to drive, many courses require participants to watch a video of someone driving while each student practices making turns and parking at their own desk in concert with the video.

The idea is to become familiar with the look and feel of driving before ever getting behind the wheel of motorized vehicle capable of causing collisions, property damage, and injury to fellow citizens. This isn’t the only instance of simulators being used for preparation – flight schools also use them, for example, and they can be used for non-training purposes, as well.

In fact, simulators can be used in a variety of business settings for a variety of purposes. They can mathematically predict outcomes, aid in risk management, and improve products and processes through simulated modeling, testing, and so on.

In terms of equipment fabrication, there are many ways in which design simulation can be used to improve outcomes.

Test New Designs

The testing process is essential when creating new products. It helps to ensure that products function as they’re supposed to and that they meet applicable safety standards.

Testing also gives you insight into potential problems and ways to improve product function and design. This allows you to give customers the best possible value and build a solid reputation as an industry leader.

However, fabricating parts, creating prototypes, and running tests can be a lengthy (and expensive) process. Using design simulation software can significantly reduce the amount of work you do and make the testing process more efficient.

Naturally, there will be some level of human involvement, but with proper input and management, computing power will do most of the work for you. The burdens associated with “going back to the drawing board” when something doesn’t work are greatly reduced when you’re running simulations as opposed to creating and testing tangible products.

Hone Production Processes

Planning production may seem like a point-A-to-point-B process, but this is rarely the case. The end game will no doubt feature specific steps in a specific sequence, but arriving at this pass requires a lot of abstraction first.

Computers are great for abstraction. The human mind works based on knowledge and experience, which are used to extrapolate ideas. In other words, we’re limited. Not so with computer software designed for simulation.

Simulation programs allow designers to approach products and manufacturing processes from angles they may never have considered. Whereas the human mind would be boggled by the endless complexities and possibilities in the design process, computers have no problem with top-down design.

This allows designers the best opportunity to test theories and figure out the ideal way to design and manufacture equipment.

Spot Potential Problem Areas

Even if a product design is perfect in theory, real-world applications could produce problems designers never anticipated. Suppose customers use a product in ways it is not intended to be used. What will happen? You need to know so that you can create functional, durable, and safe products.

Design simulators can be used to help you pinpoint, understand, and account for potential problems with your products and the manufacturing process. Virtually solving problems is bound to be a lot less difficult and time consuming than making and breaking endless parts until you get it right.

Save Money

Manufacturing new products can be an expensive undertaking, especially when you consider the initial cost of making prototypes for testing purposes, before you even begin mass production or make any sales. It’s an investment, of course, that you hope will pay off, but there are no guarantees.

Design simulations can do more than just help you to make better, safer products through virtual testing; they can also save you a ton of money on developing products that simply aren’t viable for one reason or another. Why play a game of expensive, real-world trial and error when you can get the same results at a fraction of the cost with simulated tests?

You’ll not only save money on both materials and labor, but you stand to see increased revenue as a result of making better products from the get-go. Earning a reputation for product reliability can also increase recognition, patronage, and profit.

Posted by & filed under Uncategorized.

Many businesses rely on manufacturing to produce goods for a diverse range of buyers including private customers and business clients. As the owner of such a venture, you may find that you need a variety of equipment in your manufacturing plants to produce and/or assemble parts that would be too labor intensive for workers to undertake by hand.

What you may not realize is that you have the option to create customized machinery to suit your specific needs. A special machine, or several, could provide the key to unlocking your company’s potential.

Naturally, you have to consider pricing with any equipment purchase, but when you elect to build a customized machine to aid in manufacturing, you might spend only a little more than you would for ready-made products, and you stand to gain a lot. Here are a few ways in which special machines can improve your manufacturing process.

Increase Efficiency

There are all kinds of heavy machinery options to consider, many of which can be programmed to suit your specifications when it comes to manufacturing. However, you may find that many are overly complex and difficult to utilize. They may slow your operations or perform in ways that lead to extra steps or workarounds on your part.

If you want to increase efficiency, one of the best ways to do so is with machinery that is custom made for your purposes; one that is designed to work precisely with your specs, carry out processes without extra steps, and, ultimately, increase efficiency and productivity within your operation. Once you have special machines you’ll wonder why you ever did it the old way.

Optimize Operations

The unfortunate truth about large, heavy machinery is that it is often married to third-party software that is ill-equipped for optimal function. When you have custom machines built, on the other hand, you should seek out service providers that offer custom programming to go with it.

This can help to ensure that the software performs to your specifications and that it integrates seamlessly with your existing operation (including other machinery and software). This ease of use will help you optimize operations with little fuss.

Cut Waste

Certainly you can make cut-rate manufacturing equipment work to suit your purposes, but you’re likely to end up dealing with some level of inefficiency and waste. It could be wasted materials or wasted time (or both). Either way, you’re losing.

The right special machines can help you cut waste at every turn. Not only will your production volume increase, but you’ll notice fewer issues with excess waste materials in the manufacturing process, fewer mistakes in production, and less time wasted on unnecessary steps and shut-downs to fix problems or reset processes.

When your manufacturing equipment and software is custom designed to suit your operation, you’ll see reduced waste in all aspects of production.

Save Money and Increase Profit

The bottom line is important, but you’ve no doubt heard the old adage “you have to spend money to make money”. When it comes to customized machinery, you might incur up front expenses, but the savings you’ll see with reduced waste and the increased profits you realize from improvements in efficiency and productivity should help you to recoup your costs and then some.

It's important to understand the distinctions between the various types of welding. Here's a quick tutorial of basic terminology.

Posted by & filed under Welding Fixtures.

There is no shortage of industry-specific terms associated with welding and special machines for metalworking, but before you get started, it’s probably best to understand the different types of welding you could pursue, and there are several options.  Technically, welding is characterized by the joining of pieces of metal, but welders may also engage in cutting, brazing, and soldering metal.

With cutting, metal surfaces are separated, while brazing and soldering join metal, but they generally do so with softer metals for joining and with lower temperatures (meaning these processes generally aren’t as strong or durable).  If you’re just starting out in welding, it’s important to understand the distinctions between the various types of welding.  Here’s a quick tutorial of basic terminology.

Gas

Gas welding requires a mixture of acetylene gas and oxygen that is used to create a flame hot enough to melt metal.  It can be used to melt soft or delicate metals like aluminum, bronze, and copper, as well as harder alloys like steel.  It requires greater knowledge and expertise than some other types of welding.

MIG

MIG stands for Metal Inert Gas welding, although the process is also referred to as GMAW, or Gas Metal Arc Welding.  Used for welding a wide variety of metals, MIG welding is arguably the most common type in both industrial and private settings, likely because it is relatively easy and accessible.  By this method, a steel rod is fed through the gun where it is melted so that a bead (a line of melted filler metal) can be applied directly to metal surfaces being joined.

TIG

TIG stands for Tungsten Inert Gas welding, although the process is also referred to as GTAW, or Gas Tungsten Arc Welding.  It differs from other types of welding in that a non-consumable tungsten electrode is used.  This is different from arc welding in that the electrode does not melt along with the metal.  TIG welding is cleaner than other processes, but it is also more expensive and more difficult to master.

Arc/Stick

This type of welding is named for the arc of electricity that passes between an electrode (or stick) and the metal surface being welded, creating the heat needed to melt and join pieces of metal.  Arc welding tools may be powered with either AC (alternating current) or DC (direct current) and arc welding may or may not require the use of a filler metal to join two pieces of metal.  Unlike MIG and TIG, arc welding does not involve the use of any gases.

There is a lot of other lingo you’ll want to learn if you intend to take up welding as a hobby or a profession, but having a basic understanding of the different types of welding can give you springboard from which to begin the learning process.

Eagle Engineering can help you successfully incorporate robotics with the right integrated applications to meet your company’s manufacturing needs.

Posted by & filed under Design.

At one time, the idea of robotics in manufacturing seemed like science fiction, an advancement for the distant future of fabrication. After all, as How Stuff Works points out, “break things down to the original Latin and manufacturing is literally a matter of using your hands (manu) to make things (factura).” Over the past half-century, however, robots have become increasingly popular production tools. The IFR, or International Federation of Robotics, reported: “robot sales increased by 29 percent to 229,261 units” in 2014 and noted: “sales of all industrial robots to all industries increased compared to 2013.” In a recent survey, PriceWaterhouseCoopers found that “59 percent of [manufacturers] are already using some sort of robotics technology.” Robotics are undoubtedly on the rise—if your company isn’t already using them, you probably will be soon.

As a multi-service manufacturer’s support facility, Eagle Engineering provides customized robotics solutions for our clientele. We can help you bring your operations into the twenty-first century with modern machinery and sophisticated software to match. In the following blog, we discuss robotics and the importance of having the right integrated applications for these types of devices.

Benefits of Robotics in Manufacturing

Robotics is a monumental development in modern manufacturing. Many corporations have invested in this type of technology because robotic tools can:

  • Automate key aspects of your production processes
  • Make your manufacturing more efficient
  • Improve the quality of your output with engineered precision (especially when paired with appropriate software and computerized controls)
  • Reduce your costs in labor and supplies
  • Free up employees’ time to focus on more pivotal, profitable tasks
  • Keep your workplace safe, particularly when robots automate dangerous tasks or put preventive security measures (such as screens, lights, shields, locks, or barriers) in place
  • Help you avoid the need to outsource

If you’re looking for a way to optimize your output and better serve your customers, robotics could be the answer.

The Importance of Integrated Applications

As PriceWaterhouseCoopers explains: “Industrial robots are on the verge of revolutionizing manufacturing. As they become smarter, faster, and cheaper, they’re being called upon to do more. They’re taking on more ‘human’ capabilities and traits such as sensing, dexterity, memory, and trainability.” Contemporary robots can do a lot, but can yours do exactly what you need them to? Every manufacturer has particular needs, so your robots will need to be sufficiently specialized. In order to make the most of this technology, your robotics would also ideally be multifunctional (able to perform multiple functions) and interoperable (able to transmit information to and from other machines).

This is where integrated applications come in. Each robotic device is like a new employee at your manufacturing facility. As with hiring human workers, you’ll need to choose robotics tools that can perform the required tasks and work well with your other systems. For these reasons, it’s important to carefully consider and choose the right integrated applications. A successful robot combines and coordinates various pieces of hardware and software to perform its functions.

How Our Team Can Help

If you’re ready to upgrade your manufacturing capabilities with robotics, Eagle Engineering’s team of technicians can assist you. We will help you pick, put together, or even custom make a robotic system to suit your needs and preferences. Our engineers can help you establish what you need your machine to do, develop a design for it, equip it with the proper parts, load the right software so you can guide its operations, and ensure that its components integrate well. We can also add robotic fixtures to existing machinery to improve it.

For example, we created a turnkey robotic glue application cell for one of our clients. This multi-axis robot combines with air vacuum holding fixtures and a Graco glue dispensing system to manufacture windshields. To ensure that it had the right integrated applications, the Eagle Engineering team designed and manufactured this device. Our technicians developed it to complete every operation successfully and fit in with the client’s other machinery.

Contact Eagle Engineering Today

Are you looking for a robotics solution with the right integrated applications? To learn more or schedule a consultation, contact Eagle Engineering today.

When off-the-shelf machinery and equipment simply won’t do the trick, Eagle Engineering can design customized solutions to meet manufacturers’ needs.

Posted by & filed under Design.

As anyone in a highly technical field understands, you often can’t just waltz into a shop and buy a piece of advanced machinery like you would with regular office equipment. In some cases, you can buy the parts, tools, or software you need right off the shelf. However, specialized supplies require a bit more energy, effort, and engineering to produce. Of course, having the exact instruments you need to maintain and improve your daily operations is well worth the investment. At Eagle Engineering, we’re proud to provide a wide range of support services for manufacturers, including custom equipment and machines. We understand and exceed our clients’ distinctive demands. In the following blog, we’ll explain what to do if you can’t find the machine you need on the shelf.

Why Off-the-Shelf Might Not Work For You

Are you getting frustrated trying to fit your manufacturing plans into the restrictions of predefined off-the-shelf products? If you haven’t previously experienced the advantages of customized machinery, you might be selling your business short, limiting your capabilities with prefabricated “solutions.” There are a number of reasons why off-the-shelf might not work for your needs. Ready-made equipment:

  • Is often difficult to use from a software standpoint. In an attempt to satisfy all potential clients and industries, these machines actually help none. Eagle Engineering can design a system with an intuitive interface and the capability to handle every project you tackle.
  • Often requires modification or adjustment to work at all. If you’re constantly spending time, money, and effort to tweak off-the-shelf tools for your purposes, don’t you think it would make more sense to just go custom? Eagle Engineering offers turnkey machinery for manufacturers.
  • May not exist for your particular niche. If you can’t find the machinery you need to produce your merchandise, you might actually take this as a positive sign. You need equipment like no other to create extraordinary, high-quality products.
  • Could be more affordable. Most manufacturers assume that customized machinery must come at a higher cost. However, if you consider what you’re spending to fiddle with your off-the-shelf equipment and how much productivity you’re losing over non-optimal systems, custom machinery might actually be less expensive (and more effective) on the whole.

How We Can Help

If off-the-shelf isn’t right for your project or company, Eagle Engineering would be delighted to design custom equipment and machinery for you. Our nine mechanical designers average 15 years of experience each, while our eight technical staff average 25. Altogether, we bring over three centuries of experience and extensive expertise to the table. We also collaborate effectively, utilizing each team member’s unique skills to deliver outstanding outcomes.

Should you find yourself in need a custom solution, you can simply explain what you want and we’ll get right to work on it. We’ll handle every step of the process, from concept to design to build to programming to installation. Our top priority is developing the best possible equipment for your company, so we do not favor any specific manufacturers or control systems. Our technicians can design software for personal computer-based (PC) models, programmable logic controllers (PLC), or computer numerical control (CNC). Eagle Engineering is very versatile—we can use pneumatic, electrical, and hydraulic components to devise tools for the agricultural, automotive, construction, consumer products, military, energy, recreation, and mining industries.

Once your project is complete and you’ve approved it, you can simply turn its key to begin using it right away. Of course, we can also create equipment for use at any stage of completion. We understand your time is valuable, so we strive to work as efficiently as possible. Our in-house system allows us to cooperate better and quickly solve any issues that arise. When you choose Eagle Engineering, you can feel confident that your machine will be finished swiftly and successfully.

Don’t Settle for Off-the-Shelf

Are off-the-shelf implements not cutting it for your manufacturing company? Personalized products could help you become more productive and profitable. Eagle Engineering has helped many manufacturers succeed with specialized solutions. To learn more about our services or schedule a consultation with one of our experts, contact Eagle Engineering today.

CAD (computer-aided design) software has changed the world of engineering design for the better. Learn how its innovations have improved our industry.

Posted by & filed under Design.

Digital technology has revolutionized the way we do just about everything, including and especially engineering. As a manufacturer’s support facility, the Eagle Engineering team uses some of the most advanced tools and techniques to help our clients successfully complete projects. We design machinery, new products, tools, and equipment for companies throughout the Midwest using CAD (computer-aided design) software. These programs allow us to create customized blueprints and 3D models with the click of a few buttons (and, of course, our extensive engineering expertise). We’re proud to make the most of innovations in our industry. In the following blog, we describe three ways CAD software improves design.

1. It allows Eagle Engineers to become more efficient.

CAD software combines the functions of rulers, paper, pens, pencils, calculators, specification sheets, and more into one simple, streamlined package. Our designers can instantly access all of the information they need to work on your project. In addition, if we need to correct an error or make a modification, we can simply tweak the design, rather than having to start over or struggle with erasing portions of a pencil-and-paper version.

2. CAD offers digital precision and power.

A computer can manipulate a multitude of digital variables at once, allowing us to create more accurate, detailed designs. With CAD, we can keep every facet and factor of your product in mind as we draft it. Our flexible, versatile software can adjust your design according to the materials you’d like to use, the weight it needs to be, ease of manufacturing, and serviceability. CAD’s computerized capabilities also make the complex mathematics of design simpler, since we can more easily analyze and adapt to your proposed product’s particular parameters.

3. With CAD software, we can give you a better idea of your design before we build it.

With traditional two-dimensional design, we were able to provide our clients with a rough approximation of their final products, but these on-paper models can be very difficult to interpret or imagine. CAD software generates vivid virtual 3D models of your design so you can see what it will look like and how it will function before we take it to the build stage. Of course, if you have any feedback regarding your product, we’ll tailor it to your exact specifications. In addition, since your prototype is a digital file, you can review it remotely, if you’d like, making the process much more convenient.

Our CAD Software

At Eagle Engineering, we use some of the most sophisticated software currently on the market. Our CAD programs include:

  • Pro Engineer (Pro E). Also known as PTC Creo Elements, this software provides both 2D and 3D functionality. It can incorporate and produce geometric information to produce beautiful prototypes. Pro E also can also highlight potential drawbacks of a design, optimize it, and provide important information for use in manufacturing.
  • With this software, the Eagle Engineers team can create models according to specific parameters, automatically alter them to suit specific “design intents” (the practical purposes of the product), and sketch features in two or three dimensions.
  • This software company has been providing CAD to the engineering community for more than three decades, but released the most recent version just a few months ago in March 2015. AutoCAD’s extensive capacities include rendering 3D prototypes, networking information across multiple devices so engineering teams can more easily collaborate, customization with other digital programs, and more.

When you come to Eagle Engineering, we can use one or more of these programs to create your product. Our design department is outfitted with the latest and greatest hardware and software to provide outstanding results.

Experience Twenty-First Century Design

If you want to enjoy the design benefits of CAD software for yourself, contact Eagle Engineering today to schedule a consultation with a member of our team. We look forward to working with you!

 

automated weld fixture

Posted by & filed under Uncategorized, Welding Fixtures.

A weld fixture is one of the most important tools used during the manufacturing of fabricated parts. Its purpose is to locate and secure each component of a welded part in order to repeatedly produce a quality product with maximum efficiency.

Increasing productivity, maximizing manufacturing floor space, improving quality control and creating flexibility are some of the more common reasons to consider the use of an automated weld fixture.

If you have multiple parts with common or similar features that can be ran in one fixture with changeover, automating the changeover process can significantly reduce the changeover time.

Automating the changeover process will help eliminate operator error. With preset programmable positioning the operator only has to select the part number to be ran and the fixture moves to the corresponding positions.

At times it is more practical to use manual changeover on the simple changeover features. The speed and accuracy of a manual changeover feature can also be enhanced by an automated weld fixture. With the use of the HMI (human machine interface) we can give the operator step by step directions on sequence of operation. Even though the changeover was a manual procedure an automated weld fixture; with the use of sensors; can detect and then confirm or alert the operator that he has properly executed the required changeover.

With the quick pace of market driven changes to products these days flexibility in the weld fixtures to adapt to these changes has become a necessity. With some intuitive consideration in the automated weld fixture’s design stage an automated weld fixture can incorporate extended positioning ranges to suit future product developments. It can at times be as simple as a program change in order to produce a new part in the same fixture.

In the today’s manufacturing world of fast paced product changes and new product development the use of automated weld fixtures has becoming a necessity in order to stay competitive.

 

welcome to eagle engineering blog

Posted by & filed under Company News.

Welcome to our blog! Our company is here to help you by providing superior products, services and value. Our blog was created to keep readers informed about the latest technologies in manufacturing and how these technologies can be used by the consumer and as a support forum for our new site!

What We Do

At Eagle Engineering, we strive to be a premium multi-service manufacturer’s support facility. In fact, we are well known for our expertise in turnkey support and customer service. We are able to keep a high reputation in service due to our highly skilled engineering professionals. These engineering professionals are highly experienced in finding solutions to today’s manufacturing challenges in order to help you achieve your business outcome.

Here at Eagle Engineering, we can design and build your project complete. We do so with personnel and a facility that are both equipped with the latest technology in design hardware, software, and manufacturing equipment for which we are continually updating. Our highly experienced engineers, machine technicians, welders and machinists take pride in creating and delivering superior service and products.

Eagle Engineering’s Advantage

From concept to delivery, the creation of our products is executed completely in house. Estimating, engineering, design, build, electrical, hydraulics, pneumatics, programming, installation and support are all done with our great in-house team. This gives us an edge vs. our competitors as we can drive quality, delivery, and pricing in one easy place. We are also quick to show a customer that they are more than just an order to us. We have many long-term customers and are continually looking for more long-term relationships with all customers receiving work from us. We take pride in seeing return customers and enjoy seeing familiar faces coming back to Eagle Engineering.

Our vision at Eagle Engineering is to honor our past, while making necessary improvement in becoming a manufacturer’s premier support facility. We are a dynamic company continually striving to improve. We place extreme importance on the customers’ expectations, delivering superior products, services, and value. We also place the same importance to our employees at the company, which can be seen in our highly productive work and professionalism.

Providing the best service possible is what we do at Eagle Engineering through the adherence to our guiding principles of integrity, commitment, teamwork, pride, and innovation.

We hope you enjoy our blog posts. Feel free to comment or ask us any questions!