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8 Axes

Camming

Wire Saw

Advanced Wire Saw / Winding Machine

A high-precision wire saw required eight coordinated axes, CNC-like behavior, and a complete rethink of control-loop assignments. The original architecture used the wrong loop methods. The redesign separated spool torque control, web speed control, and cam-based traverse behavior to create stable coordinated motion.

Primary challenge
Wrong motion architecture and axis role assignment.

Key insight
Different axes must serve different physical roles.

Outcome
Stable, precise cutting behavior with CNC-like coordination.

32 Servos

Hydraulics

Stage Automation

ASU Gammage Auditorium Broadway Rigging Modernization

A failing analog hydraulic overhead rigging system was transformed into a modern servo-driven platform with 32 large 8 kW servo axes, gearbox-driven hydraulic control, and a Beckhoff IPC-based control architecture. The result supports precise, repeatable, safe movement of heavy overhead stage loads for major productions and events.

Primary challenge
Legacy analog/DC controls in a safety-critical environment.

Key insight
Incremental upgrades were not enough; the architecture needed full modernization.

Outcome
High-precision, repeatable control of heavy overhead loads.

15 Years

Plant Modernization

Analytics

Envelope Converting Plant Modernization – Ohio

Over a long-term partnership, ten envelope presses were upgraded with servos, modern PLCs, and improved operator interfaces. The work extended beyond the machines to plant workflow, process piping, material delivery systems, industrial networking, and custom production-management software for downtime tracking and maintenance cost reduction.

Primary challenge
Legacy equipment and fragmented plant systems.

Key insight
Machine upgrades alone were not enough; the plant had to be redesigned as a system.

Outcome
Greater visibility, better maintainability, and long-term modernization.