Case Studies
Air-Hydraulics has created many customized machines for our customers needs. Our line of Hydraulic Presses, Air-Hydraulics Presses, and Air Presses can be easily modified to meet your form, fit, and control function requirements, or integrated into a full turnkey Press Automation System. Our design and application engineering will work with you to offer you, our customer, an affordable solution to your assembly and/or forming needs.
- All
- Air-over-Oil Presses
Case ID: 12495
Issue: Provide a full turnkey solution to accommodate and successfully assemble all the intended pump housing models, with the ability to communicate with the end-user manufacturing software system. Machine to also needed to be equipped with press guarding and safety light curtains.
Resolution: Model SIG-400 Air-Hydraulics Force & Distance Monitoring Press designed with a custom slide platen fixture and interchangeable fixtures to accommodate all the various size pump housings. The control system was designed and set-up to communicate with the customer’s internal manufacturing software system to follow and adjust parameters according to each assembly process. Equipped with full press barrier guards & safety light curtains.
Case ID: 11108
Issue: Punch / stake valve body to hold the internal spool mechanism from coming apart. Machine to have the ability to cycle up to 30 cycles per minute and be guarded in a high production work environment
Resolution: A 4-Ton Model BS Electropunch (electric impact hammer) with enclosed barrier guarding and safety light curtains
Case ID: 9916
Issue: Apply and hold pressure on a 2-piece main antenna panel assembly for an extended period of time, while the adhesive between the two pieces cured
Resolution: Custom designed 1 ton, 4-post air press with movable middle platen, complete with two-hand actuated controls with pressure initiated clamping circuit and an adjustable time-out notification indicator
Case ID:
Issue: Application required a maximum of 6,000 lb. of force to press and seat the bearing into the housing. Machine needed to cycle automatically and also needed to be equipped with proper safety guarding.
Resolution: 5.5 Ton Model C-300 Air-Hydraulics Press with two-hand initiated auto cycle, pressure initiated automatic ram return, press barrier guarding, and light curtains
Case ID: 11500
Issue: Machine needed to be up-acting and produce at least 6,000 lb. of force to press roller bearings onto its mating drive shaft. Machine was to be installed in a new integrated assembly line at one of the customer’s facilities.
Resolution: Custom designed 5.5 ton up-acting air over oil press with roller conveyor to match those used in proposed assembly line. Addition of drive shaft carrying fixtures to easily slide the shaft along the conveyor, along with slide-on tooling rings for pressing roller bearings onto the drive shafts.
Case ID: 10418
Issue: The press needed to consistently generate up to 8 tons of force in a semi-cleanroom environment, protected from outside elements during the pressing process. It also needed the ability to be automatically cycled.
Resolution: Custom designed Model C-400 Air-Hydraulics Press with an enclosed interlock guarding, auto mode of operation, and an auxiliary air tank to accommodate any factory airline fluctuations.
Case ID: 11820
Issue: Design a machine to character stamp a number of different size gear shafts. Machine needed the ability to have an easy and quick changeover feature.
Resolution: Custom Design Model-C Electropunch with an Adjustable Fixture Using Angled Gear Racks
Case ID: 13008
Issue: Ability to consistently press a hinge shaft into the mating aluminum housing at the required depth. The process needed to be repeatable, so that the assembly was manufactured to its intended design. The customer also requested some additional safety features to accommodate their factory floor requirements.
Resolution: Air-Hydraulics Model 28-A Adjustable Air Press with Positive Downstop Adjustment, Pressure Initiated Auto Return, Pneumatic Dump Feature and Press Barrier Guarding
Case ID: 12181
Issue: Ability to control the pressing force in the first operation of the fastener assembly and then control pressing distance on the final operation of the fastener assembly.
Resolution: Outfit the press with a special Electric Dual Opto-Touch Control Package, Jog Control Circuit and Selectable Pressure/Distance Ram Return alongside a Custom Designed Guarding & Light Curtain Package
Case ID: 12680
Issue: Provide a more efficient solution for the installation of metal encased seals into light truck wheel hub assemblies
Resolution: A 2.5 ton air over oil press with an end of ram gas spring pressing tool and more
Case ID: 12084
Issue: Provide a more efficient solution to eject the filtration elements from their mold cavity
Resolution: A custom design 5.5 ton air over oil press
Case ID: 11987
Issue: To provide process monitoring and verify that each part assembly was pressed together
Resolution: 15 Ton AH-Series Air Over Oil Press outfit with Force & Distance Monitoring including Data Collection
Case ID: 12604
Issue: The customer had a safety concern with their existing press and wanted a press with a two-hand control safety device
Resolution: This press was outfitted with a 3-position “Jog” circuit, which allows the operator the ability to stop the ram at any position in the downstroke by removing their hands from the finger switches
Case ID: 12731
Issue: Automate processes to puncture sheet metal multiple times for each unique part
Resolution: The press was integrated with an adjustable digital cycle counter
Case ID: 12524
Issue: This press needed to be built and configured to perform 10 unique pressing operations
Resolution: The custom programmed Human Machine Interface (HMI) allows the operator to control each process digitally
Case ID: 12307
Issue: Updating a whole set of machinery to bring operations up to speed with current standards and regulations
Resolution: Detailed cleaning and testing of all 8 machines, rebuilding of cylinders, new paint jobs, and installation of all new and updated controls
Case ID: 12231
Issue: It was of extreme importance that these pins were inserted perfectly at each step
Resolution: A Cognex Insight Vision Sensor was installed and programmed for automated error detection to ensure accuracy of the pin insertion process
Case ID: 11225
Issue: Customer required a press with quality control monitoring within their allowed budget
Resolution: Air-Hydraulics provided an affordable press force monitoring package with three modes of operation
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