Multi Test Machine

Analytical and Testing Equipment

CMM
CMM
CMM
Coating Thickness Instrument
Coating Thickness Instrument
Density Meter
Microwave Detector
Multi Test Machine
Polarimeter
Polarimeter
Protocol Line Analyzer
Radiation Detector
Refractometer

Electrical and Electronic Equipment

Special Applications

Industrial Equipment

Multi Test Machine Design

The LAB MASTER® multi testing platform was developed for Testing Machines (TMI) to consolidate a diverse range of testing devices into a single module which could be easily configured to perform the required tests.

Their product line of testing equipment exceeded 100 different products. Each testing machine was designed to perform a specific test ranging from impact testing to thickness gages. The pictures below represent a small sampling of this vast range of products.

When this product line was initially reviewed by Michael Paloian of Integrated Design Systems, the idea of product line consolidation became immediately apparent. When the concept was first proposed to TMI, numerous technical, manufacturing, ergonomic and logistic challenges became immediately apparent. Only after investing many hours of conceptualizing, brainstorming and close collaboration with TMI’s development team, did we actually begin to solve these complex problems. Today, the LabMaster represents a significant product line in TMI’s broad range of special testing machines. LabMaster modules have been configured to test everything from tensile strength, adhesion and friction to food texture.

An explanation of how this interesting project was completed is described below:

The product idea originated after Michael Paloian, President of IDS had a chance to meet with TMI’s VP of Product Development to discuss opportunities for improving the product line. Mr. Paloian was introduced to TMI’s very diverse range of products by walking through the manufacturing facility as well as viewing products in the showroom.

After this inspirational meeting, Mr. Paloian suggested the possibility of reducing product configurations and SKU’s by developing a modular system that could standardize the product line. The result of this meeting was a corporate directive to modularize the entire product line with a modular system which would consolidate parts, standardize products, lower costs, and reduce product development times. The products were classified by TMI into four (4) product groups:

Linear based testers ( fast and slow)
Dart based testers
Pendulum based testers
Clamp based surface testers

The design and development progressed through the following phases:

Phase 1: Product Line and Market Research

The program was initiated with a thorough examination of the entire product line based on the following parameters:

Physical attributes
Purpose and classification
Specifications
Internal components
General Operation
ASTM test name
Physical sample shape and size
Selling price
Annual production volume

Each product was classified by IDS and grouped according to size, function, internal components, and other common denominators.

After the classification process was completed, evaluated, and approved, IDS consolidated the product line by designing a base module that could be configured to emulate the function of any test machine in the product line. Throughout this process, Testing Machines' management staff provided technical expertise to optimize the modular system while our design team designed the modular system architecture.

During the development of this modular system, components were modeled in 3D CAD Numerous assemblies were configured to demonstrate how the system emulate each product.

In addition, foamcore models were constructed to physically represent each system concept. The models permitted TMI management to physically interact with the proposed system to evaluate size, feasibility and man-machine interface.

Phase 2: Concept Development for the Lab Master

After Phase 1 was completed, specific concepts representing the exterior shape of the base module were developed in sketches and eventually in 3D CAD. Developing initial concepts in sketch form provided a rapid method of exploring numerous ideas quickly and spontaneously. Preliminary sketched layouts of internal components permitted our design staff to explore various enclosure shapes based on internal component arrangements as illustrated in the sketches below:

The layout sketches were later applied to the exploration of numerous styling concepts as shown in the following sketches:

These concepts illustrated alternative design options based on various component arrangements. After the layouts were created, a second set of white foam core models were constructed. These models enabled everyone to readily appreciate physical size and overall shape of each concept. Three (3) concepts were completed and presented to Testing Machines at the end of this phase.

Phase 2 concluded with a presentation of renderings and foam core models for the new modular Lab Master system defined in Phase 1. Design details were limited to overall physical appearance based on the general specifications stated below:

The enclosure was designed to support all electronic components
Ventilation was integrated into the overall appearance to satisfy thermal requirements.
The enclosure was designed for either horizontal or vertical orientation
The enclosure was designed to permit users to mechanically fasten many test modules to a rail to emulate numerous tests dynamic tests.
A hardened top surface insert was provided to conduct mar and abrasion resistant testing of moving paper.
Our experience with emerging technology at that time convinced our client to replace a membrane keypad and a 2 line LCD with a touch screen display.
The design permitted the electronic module to be oriented either vertically or horizontally, depending upon the testing machine’s requirements.

In addition to the general specifications listed above, our design team assisted TMI in identifying purchased components, manufactured items, and modified subassemblies for all components affecting all enclosures. Other factors affecting design included:

Engineering and performance criteria
Operation sequence for each module
Details for the sample holder
Partial details for each test module layout
Outline for the preferred manufacturing assembly steps and parts
Service issues
Shipping requirements

After the concepts were evaluated by TMI, a design direction was established and selected for further development throughout the remainder of the program.

Phase 3: Production Design Detailing

The selected design was completely detailed into a set of production ready parts and subassemblies to satisfy all product requirements. Every manufactured part and specified hardware required to manufacture the enclosure was included within a Pro-E 3D solid model assembly. Parts were designed in accordance with the selected manufacturing process and detailed in a 3D assembly which was eventually used to generate a complete set of production drawings. All molded or cast parts were detailed with appropriate draft angles, tolerances, and hardware suited to the specific manufacturing process. Sheet metal parts were designed with appropriate bend radii, tolerances, and mounting hardware.

A close communication with TMI’s engineering and management staff was maintained as the design evolved through each stage of development. Communication was maintained with data sharing. e-mails and real time web meetings. Misinterpretation, undesirable design details, and program delays were eliminated since TMI will be continually appraised of the developing design.

At the end of Phase 3, TMI received one set of 3D solid geometry files for the electronics enclosure, operator interface module and covers for a testing linear module. Cad data was transferred to TMI in IGES and Pro-E format. In addition to transfer of CAD files TMI also received cost estimates for tooling and part costs the enclosure based on the following vendors:

Metal investment casters
Plastic casters and stereolithography prototype shops
Aluminum extruders
Machine shops
Sheet metal shops
Thermoformers

Phase 4: Functional Prototype and Design Revisions

After the production design was completed in Phase 3, our staff sent drawings to specific vendors to construct a pre-production prototype based on the CAD file. IDS obtained bids from a minimum of three vendors specializing in each manufacturing process including rapid prototyping, sheet metal and machined parts. During the prototyping process our team interfaced with these facilities to answer questions and provide technical support. We also provided TMI with technical assistance during the assembly of the first prototype. Minor design modifications were made to the design and preliminary production control drawings after the prototype was evaluated and finalized by TMI. Phase 4 was completed after the prototype and minor design revisions were included in the 3D assembly.

Phase 5: Production Part Drawings

After the design was prototyped and approved by TMI, a set of production drawings based on the final production design were completed by our design team. Production control drawings were created for purchased parts or modified parts. Drawings included critical tolerances, surface finish, draft and all other pertinent information required to fabricate each part. All 3D models and associated 2D part drawings were modified to comply with TMI’s final design specifications. Production documentation included geometrically toleranced part drawings to assure production consistency in critical areas.

The final documentation package included assembly drawings, subassemblies, cast drawings, and machine detail drawings. Material specifications, tolerances, finish, color, draft and other pertinent information were called out on every part drawing. Plastic molds were machined directly from 3D CAD files developed by our design team.

Phase 5 was completed after all part drawings were reviewed and TMI received a 3D IGES file of all parts as well as a complete set of production part drawings in DXF or DWG format. Also included were assembly drawings, a bill of material and a set of Pro-E files.

Vendor Liaison and Production Follow-up

During production tooling and startup IDS provided TMI with technical by answering questions pertaining to tolerances, surface finish, design modifications, or any other issues, which typically arise when parts are manufactured or assembled.

Since its introduction the Lab Master® product line has grown into a significant portion of Testing Machines’ product line. Below are a few of the many different Lab Master configurations offered by TMI in its current product line.

ZDT Tester is a precision PC Controlled testing instrument which automatically determines internal bond strength according to TAPPI T 541. All testing parameters such as test speed, dwell time and compression force are selectable in an easy to use, intuitive software program supplied with the instrument.

PRECISION TESTING

Peak Force is measured to a maximum capacity of 1100 N (250 Lbs) with a 0.04 N (0.01Lbs) resolution and accuracy of ±0.5% of reading. Position is measured and controlled with 0.1μm resolution and 0.2 μm repeatability. Peak force is measured by applying a force in the z-direction until ply separation occurs.
Lab Master Z-Directional Tensile Tester photo 2.

APPLICATIONS

ZDT measurements are an effective tool for monitoring a variety of strength properties which aid in improving printing and coating applications, bonding strength of paper cores, delamination strength, intrinsic fiber bond strength, paperboard and combined board strength and fiber-to-fiber bond strength.

Additional Links

Integrated Design Systems Inc.
33 Great Neck Road
Great Neck , New York 11021