Engineering Portfolio
A closer look at the electro-mechanical systems and software architectures we've deployed.
Case Study: Concentricity Station
The Challenge
Podmore Manufacturing faced a bottleneck with manual microscope inspection of copper pins. It was slow, inconsistent, and costly.
The Solution
A custom 5-stage interlocked machine featuring:
- 1. Orientation: Vibratory bowl aligns pins vertically.
- 2. Transfer: Linear vibratory track stabilizes the feed.
- 3. Presentation: Mechanical presenter holds and positions the pin.
- 4. Inspection: Adjustable laser scans for 50µm concentricity.
- 5. Sorting: Automated gate filters results into Pass/Fail bins.
Case Study: Automated Vision & Assembly Verification
The Challenge
A leading manufacturer of intelligent waste management systems required an automated quality control station. Missing rivets on their final assemblies could lead to structural failures in the field, and manual inspection was causing massive data-logging bottlenecks.
System Architecture & Integration
Partnering with Cognex hardware, we architected a complete end-of-line verification system. We engineered the inspection frame using modular aluminum extrusions and modeled custom fixturing in 3D CAD for repeatable part presentation.
- 1. Part Detection: Proximity sensors verify the assembly is locked into the jig.
- 2. Traceability: A Cognex scanner automatically reads the barcode to generate a unique data log.
- 3. Vision Inspection: Cognex cameras are triggered to analyze the presence and proper seating of all structural rivets.
- 4. Operator UI: A custom stack-light guides the operator (Yellow = Ready, Green = Pass, Red = Fail).
- 5. Data Pipeline: Results are parsed and uploaded directly to the client's internal IT database for QA tracking.
Phase 1 Engineering: 3D CAD Mechanical Design & Sensor Mapping
Case Study: Lab-as-a-Service & Remote Test Architecture
The Challenge
Scaling high-energy lithium battery R&D requires massive capital overhead for testing channels, thermal chambers, and catastrophic failure mitigation. R&D teams needed a way to execute rigorous, IEC/GB compliant cell testing securely without owning the physical infrastructure.
System Architecture & Integration
We architected a complete "Lab-as-a-Service" facility from the ground up, bridging industrial test hardware with a secure IT backbone for remote-access client control.
- 1. Secure Network Architecture: Engineered a custom web portal linked to an in-house server. The server acts as a secure gateway to an isolated VLAN where all equipment lives—allowing remote control without exposing the machines to the public internet.
- 2. High-Capacity Cycling: Commissioned and integrated 200+ testing channels synchronized with thermal chambers (-40°C to 150°C) for multi-format cell evaluation.
- 3. Edge AI: Deployed a local LLM assistant via RAG architecture to autonomously convert natural language requests into compliant test scheduling and data analysis.
- 4. Hazard Engineering: Designed custom explosion-proof testing jigs and integrated automated fire suppression logic for catastrophic failure mitigation.
Gateway & Telemetry DB
Protocol Generation
(-40°C to 150°C)