Air Driven Hydraulic Intensifier Cuts Costs Compared to Hydraulic System

Challenge

A food packaging company needed to generate large forces at the end of stroke in one of their applications to provide a tight seal. Their existing machine design required them to provide pressurized hydraulic fluid by pumping the fluid into a tank that stored the pressurized fluid until it was needed. This resulted in a costly hydraulic circuit that required a significant amount of floor space.

Solution

To solve this problem, Bimba developed an air/oil cylinder intensifier. Using an integral hydraulic reservoir with a 2” bore cylinder, this design generated over 6,000 lbs of force to intensify the hydraulic pressure over the last inch of stroke. In addition, the compact design proved to be cost effective, taking up less floor space than existing applications.

Other Applications:

  • Conveyors
  • Lift Tables
  • Presses
  • Heat Seal Press
  • Joining
  • Punching
  • Marking
  • Coining

Benefits:

  • Eliminates external hydraulic tanks and pumps, which saves $500-$1000 per system
  • Integral hydraulic reservoir eliminates the need for a larger compressor to achieve higher pressures
  • Compact design cuts down on floor space


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Air Driven Toggle Clamp Saves Time & Money versus Manual Clamps

Challenge:

A manufacturer of window frames was using anywhere from 4 to 30 manual toggle clamps to hold multiple boards in a fastening application. With an inventory of over 100 custom forms with each taking a different number of clamps, this process was labor intensive and time consuming. They were also experiencing problems with the clamps not releasing completely out of the way once the frame was built. They wanted to reduce the number of clamps they were using in order to save time and money, while increasing productivity.

Solution:

Bimba developed a clamping cylinder that provides “1-stop locking” using pneumatics. Upon actuation, the cylinder rotates the clamping fingers into position. When pressure is released, a spring returns the fingers to the home position. This design gave the customer the ability to vary the locking force by simply adjusting the air pressure. By using a rack and pinion design from Bimba's traditional rotary actuator, the clamping fingers can rotate over 90°. This allows the clamp to fully release away from the assembled frame via a spring returning design, reducing labor and saving time throughout the entire manufacturing process.

Bimba’s engineering team provided a single solution for all the various frame geometries by offering adjustable length clamping fingers and the ability to have either a single clamp or dual clamp. By reducing the quantity of clamps needed, the customer cut their total set-up costs in half. This also reduced labor and the overall time for the manufacturing process by 30%.

Other Applications:

  • Carpentry/Woodworking
  • Welding
  • Various Types of Molding Applications
  • Workholding Fixtures

Benefits:

  • Decreases quantity of clamps used, cutting total set-up costs in half
  • Reduces manufacturing process time and labor by 30%


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Automated Glue Dispenser Generates Higher Production Yield

Challenge:

A laminating company needed to develop an automated glue dispensing system that would glue an 8 ft long corrugated piece of plastic onto a flat, smooth piece of plastic. This required 48 dabs of glue, or 1 dab every 2 inches across, to be applied uniformly and simultaneously. With the plastic sheet being fed continuously, the glue would be dispensed automatically after every 2 inches of feed. After rejecting a costly robotic solution, they decided to look for something more cost efficient.

Solution:

Bimba developed a maintenance-free cylinder that would dispense glue when the rod retracts. Glue is continuously fed to the cylinder using a 9 ft long reservoir with 48 mounting locations, or one for each glue dispensing cylinder. The reservoir simplified the glue supply to each cylinder and was also sized to hold enough glue for a full shift of work. Pressurizing the reservoir made each dab of glue consistent from one to the next. Vertical motion required to raise and lower the cylinders when dispensing the glue was accomplished using Bimba’s standard Flat-1 cylinders.

Other Applications:

  • Fluid Filling/Dispensing
  • Sealing/Adhesion
  • Hole-Punching

Benefits:

  • Cost effective pneumatic solution saves thousands of dollars compared to alternative robotic solution
  • Automated process results in glue dab consistency, leading to higher yield


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ID Gripper Reduces Downtime 30% by Eliminating Expensive
Replacement Bladders

Challenge:

A polished finish on the outer diameter of a tube required a customer to pick and place these tubes using a bladder style internal gripper. The deflated bladder is placed inside the tube and then inflated, providing pressure to grip the tubing. The bladder design was susceptible to incidental piercing damage, due to metal burrs and rough edges on the inside of the tubing. This resulted in costly downtime and expensive replacement bladders that cost up to $100 each.

Solution:

Bimba developed a unique internal gripper design using a standard Original Line Cylinder and a piece of flexible urethane capped on both ends. The resulting design eliminated the piercing damage, providing a gripping design that is easy to maintain. This reduced downtime to replace the punctured bladders by 30%, and saved thousands annually by eliminating the expensive replacement bladders completely.

Other Applications:

  • Fragile Material Handling
  • Sorting
  • Leak Testing
  • Pick & Place Equipment

Benefits:

  • Reduces downtime by 30%
  • Eliminating replacement bladders saves thousands of dollars annually


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