Reverse Engineering of Payoff Machine
- Category: Automation
This project focused on reverse engineering and upgrading a well-designed wire drum payoff machine. The equipment was originally developed to maintain precise tension control across six wire spools, each with independent adjustment capability. Built specifically to meet the client’s production needs, the machine served effectively on their shop floor for many years.
Our scope of work was divided into three key phases:
Phase 1: Reverse Engineering & Engineering Drawings
We began by reverse engineering the existing machine. Our engineering team visited the client’s facility to:
- Capture all critical measurements from the machine in operation
- Identify and catalog standard components sourced from suppliers
- Redraw all custom, non-standard parts
- Compile a full set of engineering drawings suitable for RFQ (Request for Quotation)
This phase was essential in laying the groundwork for future manufacturing, upgrades, and maintenance.
Phase 2: Load Capacity Analysis & Design Optimization
Next, we conducted a detailed load analysis to verify the machine’s structural integrity and ensure long-term durability. Using FEA (Finite Element Analysis) and practical stress evaluation:
- Areas subject to fatigue were reinforced for improved performance
- The drawings were updated to reflect structural improvements
- A complete assembly drawing was developed to assist both manufacturing and future maintenance processes
Phase 3: Tension Control System Upgrade
In the final phase, we enhanced the machine’s usability by upgrading the tension control system. Originally located on the machine’s frame, the control was replaced with a remote pendant operated by hand. This change:
- Improved ergonomics and safety
- Significantly reduced production downtime during tension adjustments
- Gave operators greater flexibility and ease of use
This phase was essential in laying the groundwork for future manufacturing, upgrades, and maintenance.
Phase 3: Tension Control System Upgrade
In the final phase, we enhanced the machine’s usability by upgrading the tension control system. Originally located on the machine’s frame, the control was replaced with a remote pendant operated by hand. This change:
- Improved ergonomics and safety
- Significantly reduced production downtime during tension adjustments
- Gave operators greater flexibility and ease of use
This phase was essential in laying the groundwork for future manufacturing, upgrades, and maintenance.
This project not only revitalized an aging machine but also equipped it with modern upgrades tailored to our client’s evolving production needs.
