Pan-Tracking

Justin Wand on November 4, 2020

MJ Engineering does a lot of work for numerous companies. We work on everything from coal mines to amusement park rides to robotic systems. This particular case was designing a highly sophisticated system that could scan and upload data about pan usage in a bakery.

~ J. Wand

Problem:

A large pan manufacturing company approached MJ Engineering with a technical issue. They had baking pans that were coming back to them with claims made that the pans weren’t meeting the warranty that the company stated. The company, confident in their product, asked how the pan cycles were being managed. Upon hearing how the current process worked they reached out to us and asked if we could help them. The goal was to create a system to help with the pan life cycle tracking.

Solution:

To solve this problem, the Pan Tracking System was born. The Pan Tracking System reads a laser-etched code on the bottom of each pan and keeps a log of it. The log is eventually uploaded to an FTP site where it is compiled and both the pan manufacturer and bakery can see all of the tracking data. The main goal of this System was to track pan usage and lifespans.

How does this work? The pan comes into the Pan Tracker and the system has a camera mounted on it to read the barcode. Each time a pan passes by the Pan Tracker system, a sensor is triggered to activate the scanners to read the code on the pan. Every pan code is logged as it passes by the Pan Tracking system. After the data is collected for two hours the log file can be uploaded to an ftp site where it is compiled onto a website where the information can be examined to determine the usage.

Result:

The result was that the company determined that in fact the pans were meeting the warranty. Now they actually have the data to prove it though. The company is able to track the amount of usage of 1 pan and compare it to another pan in the same set to make sure usage numbers are balanced appropriately. This makes tracking the pans exponentially easier and more efficient. The system is easy to run and can be installed by a knowledgeable in-house maintenance crew with the easy to follow instructions provided.

Challenges:

There were a few challenges to work around in this project. The biggest problem encountered in this process was actually getting the codes onto the pans. This was because of a combination of a few things. The original plan was to use adhesive stickers with a barcode to stick onto the pans. However, the stickers fell off after high numbers of heat cycles. Which led us to have to try something new. The result was to laser etch the code onto the actual pan. This prevents the code from falling off.

What Does This Mean to You?

Before you settle for the quick fix that solves the initial issue but not the root cause of the problem, step back, and analyze the underlying issues, and call us at MJ Engineering (614-891-6111). We specialize in developing the custom solution that will help your business become more efficient, profitable and sustainable.

Amusement Parks

Justin Wand on November 4, 2020

Amusement Parks

10 years and counting. MJ Engineering has been in the amusement industry for 10 strong years doing 50+ projects in this time ranging from small to large projects. We can provide finite element analysis or come on-site and run tests such as 3rd party testing, strain gauge testing, wall thickness testing, or simplified accelerometer testing. We can certify rides to ASTM F24 standards and help with ride design, or repair. We will help with any ride new, old, or orphaned.

Orphan Rides are generally, rides in which the original manufacturer is no longer willing or able to support the ride. We can help you support those rides. Call us and we can set up an on-site evaluation. We can perform numerous tests on your ride, assist with repairs, and many other things. We have professional engineers licensed in Ohio, West Virginia, Pennsylvania, Indiana, Georgia, Kansas, Missouri, and Iowa. We have successfully gotten rides approved in New Jersey as well.

Changing rules and regulations is a common occurrence since The Ohio State Fair accident. Many states have altered or even created brand new regulations, departments, etc… since the Fireball accident. We work around all F:24 standards including 2291, 1918, 2970, 2959, 1193, and 770. Another reason for the change in the world of entertainment is Covid 19. This virus has altered the way all parks around the country have operated. Some have not opened and some have limited capacity. If you need to modify your ride to meet Covid regulations, give us a call to discuss.

MJ Engineering should be your first call when considering your rides. We have professional engineers who understand physics and dynamics behind the rides while also understanding complex mechanical systems and the importance of uptime and efficiency. The advantage of using MJ is that we are extremely strong on the engineering side.

Needless to say, our company is extremely competitive with anyone and will work as hard as possible to make sure the job is done to the best of our ability.

Need a quote call us at (614) 891-6111 or email us at jwand@mjengineering.com.

Manufacturing Transitions: Moving Between CNC Machining and 3D Printing

Justin Wand on November 4, 2020

– Bailey Hudson

Neither CNC machining nor 3D printing is a new technology. Computer Numerical Control (CNC) has been around since the 1950s, while 3D printing was invented in the mid-1980s. But both technologies are in increasing use today. CNC has become one of the dominant machining methods, with CNC lathes, mills, and routers fast becoming the standard.

As for 3D printing, technology has taken off in recent decades years. With its ability to produce almost any shape, many manufacturers have started to ask about the exact relationship between CNC machining and 3D printing. How do the two technologies work? Can they be used together? Will it ever be possible, or practical, to abandon CNC altogether for 3D printing?

In this article, we’ll look at some of those questions, and suggest some ways that a manufacturer could use both methods in conjunction.

Similar goals, different methods

Both CNC and 3D printing are machining manufacturing techniques, but they take a radically different approach. CNC is a subtractive process whereas 3D printing is an additive process. With CNC, Tto make a cylinder, for example, you might begin with a vaguely rectangular shape, then use a lathe to machine away excess material until the workpiece was cylindrical. The resulting piece will be smaller than the one you began with; you’ve removed material to make the part.

3D printing is the exact opposite. With 3D printing, you begin with no shape at all – simply the printer itself and a metal powder as raw material. The powder is used to slowly build apart from the ground up, adding material layer by layer.

Additive machining manufacturing provides a whole new approach for manufacturers. 3D printing can produce almost any shape, including geometries that might be difficult to achieve through subtractive machining. The potential applications for 3D printing are nearly limitless, with special potential for prototyping and R&D.

Pros and cons

So why not simply abandon CNC subtractive machining-manufacturing and move everything over to 3D printing? Why not stop cutting metal parts (subtractive machining-manufacturing) and only build them instead (additive machining manufacturing)?

Unfortunately, 3D printing does have some drawbacks. First and foremost, the process is quite slow – far slower than the various subtractive machining processes. Large-scale, industrial-sized projects would require a much longer time to build than to cut, particularly if there is a large number of parts to produce. Thus, one of the first questions many manufacturers use to determine the correct method to use is simply to ask, “how many parts do I need?” If the answer is a large number, CNC is likely to be much faster and more efficient. 3D printing also produces parts with much larger tolerances than CNC machining, meaning the parts can be a bit rougher and still in need of finishing.

Two are stronger than one

The greatest potential for both methods comes when they are used in conjunction with each other. For individual parts, 3D printing provides a way to produce one-off or small runs of parts with geometries that would be difficult to cut on a CNC machine. After the 3D printing is complete, the same part could then be subtractively machined via CNC to finish surfaces, insert threaded holes, or any number of other machining steps.

The two methods can also be used in the overall workflow. 3D printings excel at producing prototypes and models, parts that are often one-off productions or require small numbers, and where the time pressure is not great. Once a part has been prototyped and the design refined, a CNC program can be made that allows operators to produce the part in far greater quantities on a CNC lathe or mill.

Used in this way, the manufacturing process starts with additive machining manufacturing and then moves to subtractive machining-manufacturing, to produce even a difficult or completely new part with tight tolerances.

Back and forth

Using CNC machining and 3D printing isn’t a matter of transitioning entirely from one to another, but of using both technologies at once. In the real world, that means being flexible and deciding on a case-by-case basis which method is best for a given part.

Introducing Metal X

Justin Wand on October 27, 2020

NOW INTRODUCING METAL X

Metal X is a 3D Metal Printer that can Print:

-17-4 Stainless Steel

-D2, A2, H13 Tool Steels

-Copper

CUSTOM PARTS IN HOUSE

SpikeEase

Justin Wand on October 26, 2020

Overview

MJ Engineering collaborated with Focused Technologies to develop the award-winning (Best Maintenance of Way Product 2020) and patented SpikeEase railroad spike remover. The SpikeEase project originated as a college senior design project, which MJ Engineering completely redesigned to make stronger, lighter, more powerful, more ergonomic, and easier to use. This product utilizes a customized acme screw and acme nut that when turned by an off-the-shelf impact wrench uses leverage to pull the spike out of the tie. This product is an investment in safety and productivity that pays for itself by increasing production, reducing injuries, and eliminating the need for hydraulic equipment or claw bars. The SpikeEase is designed to be the lightest, easiest, and most eco-friendly spike remover in the world.

According to Focused Technology Solutions, the SpikeEase is the world’s most advanced battery-operated spike remover. Eliminating the need for hydraulic systems means un-tethering employees from service vehicles, heavy hoses, and expensive hydraulic power units.

Goals

Design a battery-powered spike remover
Improve maximum pull force
Reduce the cost of and weight of the SpikeEase.
Improve the ergonomics of using the SpikeEase in the field every day.
Improve the strength and useful life of the SpikeEase

Specifications

Weighs in at 30 pounds (not including drill or battery)
3-7 seconds per spike removal
A rechargeable battery pack and a commercially available drill
Easy to transport anywhere the rail takes you
No hydraulic system to risk leaks and environmental hazards.