CUSTOM EQUIPEMNT DESIGN & DEVELOPMENT PROCESS
Primary skills of Cominus are design synthesis and technology integration. To make sure that the equipment we produce meets or exceeds the expectations of our customers in terms of shape, function, cost, and timing, it’s critical to incorporate the proper amount of technology for the application. There are process-specific machine types inside each of the three primary machine categories that Cominus creates (Composites Automation, Supercritical Fluid Processing, and Industrial Automation). Simple, efficient, and customer-focused, the Cominus Custom Equipment Design & Development Process:
Concept Development
Customers and Cominus developers meet to discuss requirements and determine the scope of the project. A brainstorming session bringing together interdisciplinary ideas from a broad team of engineers, designers, and fabrication employees introduces in the conceptual design development process. Internal brainstorming meetings with team members who have expertise in engineering, software, CAD design, and manufacturing are held beginning in the early research stage and continuing throughout the project to ensure that we completely cover all important parts of it. Our engineers and designers compare the performance, availability, compatibility, and cost of all the key systems and parts of the suggested solutions. Customers that wish to test a theory in a bench-top experiment before committing to a larger study can benefit from our own research and experimentation capabilities.
Our own machine, material, and machinist resources can swiftly construct experimental setups in support of Technology Development or Risk Reduction activities. When new information from testing indicates that changes are necessary, our machinists are able to make adjustments immediately. A major design direction is selected at the project’s concept review, which marks the end of the Concept Development phase and serves as the basis for the Preliminary Design Phase.
Preliminary Design
The Cominus team starts to detail essential parts of the equipment aggressively, building on the Concept Development Phase’s work. Researching component combinations and the many suppliers of them is part of the specification process. This study entails gathering data on prior experiences with a product or vendor, soliciting feedback from people who have used the product or vendor, comparing product literature, speaking with representatives from the vendor regarding component choices, and/or visiting vendor facilities. Form, fit, function, cost, and lead time are the main factors in component selection. The engineers create the primary skeleton or equipment structure after choosing the components. The mechanical, electrical, and pneumatic systems are then first-pass 3D models made by the CAD designers in Autodesk Inventor for additional study. At this point in the project, the complete electronic design notebook has been fully filled with everything from preliminary thoughts to cut sheets for specific components. In a rigorous design review at the end of this stage a.k.a. “Preliminary Design Review (PDR), the customer and Cominus engineers review all aspects of the proposed design. In order to get ready for the comprehensive design phase, issues are rapidly and effectively addressed during this meeting or shortly after.
Detailed Design
Following the PDR, work on the Detailed Design begins immediately. This phase thoroughly specifies all components in order to fill mechanical, electrical, pneumatic, and/or hydraulic bills of materials (BOMs). The 3D CAD models are completely filled with complete information for all produced and bought items. Electrical CAD designs include circuit layouts with all wires labelled and cabinet layouts dimensioned. All purchased parts are fully specified, and all relevant information from BOMs, detailed drawings, and component cut sheets is added to the electronic design notebook. When the Critical (or Final) Design Review (CDR) is completed, the project’s Detailed Design phase is complete. The client grants consent for the manufacturing of the equipment, which begins with Procurement and Fabrication, at the end of the CDR or shortly thereafter.
Procurement and Fabrication
Following design approval from the CDR, support staff and engineers begin writing Purchase Orders (POs) and assembling Fabrication BOMs. Cominus has in-house mechanical and electrical fabrication departments that are skilled in a variety of production processes. Although we occasionally use external machine shop resources, having in-house fabrication facilities and personnel allows us to closely monitor quality and control delivery schedules. Our experts and machinists can create components that are too expensive to buy from a commercial source. Cominus’ in-house manufacturing plant can produce all non-commercial components, including hydraulic, pneumatic, electrical, and mechanical assembly.
Assembly
Components that have been fabricated or acquired are stored in our facility’s flexible production and assembly area until they are ready for assembly. The bill of materials (BOM) is used to track component manufacture and procurement, ensuring that all components are purchased and organised in the receiving area. If any assembly issues that require immediate resolution arise, technicians have direct access to Engineers and Designers for the equipment. Engineers ensure that equipment assembly continues in accordance with the assembly drawings of the authorised design and that the equipment fulfils the form, fit, and function of the design as technicians wire, position, and secure each component and install safety guards to protect operators. Any modifications or changes are red-lined on the master set of drawings.
Factory Acceptance Testing
Cominus performs equipment starting and operates every piece of equipment before it is given to the client to guarantee that it meets or exceeds customer expectations. This Factory Acceptance Testing (FAT) is crucial to ensuring the equipment’s successful commissioning at the customer’s location. Our mechanical engineers ensure that all mechanical and pneumatic systems are correctly operating. All sensors are aligned and all electrical systems are tested by electrical engineers. The operator interface, safety interlocks, and production programs are thoroughly tested by our software developers. When the FAT is finished, the equipment is crated and shipped to the customer’s location.
Installation, Training & Support
Cominus arranges for the equipment to be transported to its new location, uncrates it, reassembles it as needed, integrates it with the current client equipment, and tests it again [Site Acceptance Testing (SAT)] to ensure correct operation. We offer onsite operator training for normal equipment use, as well as in-depth diagnostics, maintenance, and programming training for advanced operators/engineers and equipment maintenance professionals. An operator’s handbook is included, which includes information on safety protocols, troubleshooting, normal operating instructions, and maintenance. Because our machines are frequently unique, one-of-a-kind, and/or ground-breaking, problems may arise after machine commissioning. When you need help, Cominus will be there to debug, fix, and get you back on track. Our engineers also offer phone and on-site technical assistance.