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We thrive on tailoring each project to the needs of our customers, whether they be speed, accuracy, full automation, integration into your existing systems, or high quality solutions for strict budgets. Check out our case studies to learn more about our capabilities and expertise. Want to learn more about JR as a company? Check out our latest brochures.

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Case Studies

Case Studies

Robotic Visor Assembly Cell
Power Liftgate & Laser Weld Station
Friction Stir Welding
Heated Edgefold Upholstering & Trim Press
Automated Swing Arm Bearing Press
Antilock Brake Sensor Machine
Flexible Welding Cell
Cabinet Face Frame Assembly Cell
Coolant Reservoir
Vision Guided Robotics - Flex Feed
Automated Barcode System
 
 
Robotic Visor Assembly Cell
Type:   Plastic Processing
Level of Automation:  Medium

Challenge
To assemble and test right and left hand fabric covered sun visors on a single assembly system with minimal operator contact and a 15 second cycle time. Cleanliness is important to avoid staining the light colored fabric.

Solution
The JR team created an effective assembly solution by integrating several different assembly processes and part handling methods which decreased cycle time, reduced labor content and floor space, and improved part quality over the customer's existing stand alone assembly cells.

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Power Liftgate & Laser Weld Station
Type:   Plastic Processing
Level of Automation:  Medium

Challenge
Our challenge was to develop a machine that used a laser to weld components of a liftgate actuator through its plastic outer-layer. The machine needed to accommodate three part types with minimal changeover. Complete cycle time for this machine, including operator load and automated unload needed to be under 25 seconds.

Solution
The JR team incorporated a custom-designed LPKF Laser Welder to weld the plastic actuator components together. A laser-weld head, controlled by a servo/ball-screw module and cylinder, used a high-power diode laser system to weld several key points on the liftgate actuator. A separate servo rotated the weld fixture in place, allowing the laser-welder to provide accurate laser delivery to the circumference of the part.

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Friction Stir Welding
Type:   Metal Processing
Level of Automation:  Medium

Challenge
Take the welding process, for example: many parts of manufacturing a vehicle depend on the marriage of metals. In traditional arc, MIG, and TIG welding, metals are fused using intense heat and a molten filler metal. When the metals cool and solidify, a bond is created between all of the materials. This process creates a strong weld, but adds weight to the original material. Additionally, arc, MIG, and TIG welding use a great deal of energy to produce heat to melt the metals. In some cases, the heat used to weld two surfaces warps the part, causing the part to be rejected, and ultimately wastes time, money, and material. As the world moves towards cleaner modes of transport, changes in the way materials are welded are necessary.

Solution
At JR’s Quality Drive facility, the PaR Systems I-Stir, a top-of-the-line friction stir welder is being used to join two aluminum plates side-by-side, using a nickel-cobalt alloy pin to stir the aluminum. The aluminum plates will eventually become a large component of a car. Since the product has no added material, the end result, post-weld, is a lighter, more energy-efficient vehicle.

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Heated Edgefold Upholstering & Trim Press
Type:   Plastic Processing
Level of Automation:  Low

Challenge
Develop machines to press laminate three part types, with additional parts types to come in the future. Two critical elements for the press are constant heat for bonding, and preventing wrinkling and puckering of the fabric.

Solution
Because all three of the parts require a similar process-a vertical press, horizontal actuators, and heat-the JR team designed one safety and control system with multiple rolling tooling carts; a huge cost savings for the customer.

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Automated Swing Arm Bearing Press
Type:   Metal Processing
Level of Automation:  Low

Challenge
Provide a machine that ensures parts are free of flash and installs bearings with the correct force and distance.

Solution
The Automated Swing Arm Bearing Press is an all inclusive machine with poke-yoke capabilities, robust integrated equipment, fast and efficient bearing installation and customized floating C-Frame design.

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Antilock Brake Sensor Machine
Type:   Other
Level of Automation:  Low

Challenge
Design and build a machine to international standards for assembly and testing of small parts, within a tight budget.

Solution
A tight budget minimizes choices, but maximizes the creativity of the engineers at JR. In this case, the result is a smaller, finely machined, lightweight assembly solution that produces to close tolerances. The machine uses automation to feed and press terminals into housings, and then to verify quality.

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Flexible Welding Cell
Type:   Metal Processing
Level of Automation:  Medium

Challenge
Design a weld machine for low volume production runs of more than 100 different part types.

Solution
The JR solution uses a material handling robot to pick and place fixtures from a rack, which it then presents to an operator for part load and to the weld gun for welding.

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Cabinet Face Frame Assembly Cell
Type:   Other
Level of Automation:  Medium

Challenge
Customer needed a cell that could assemble face frames without the existing manual labor.

Solution
Taking into account the tradition of cabinet building, the JR team integrated the newest software technology on the market to develop a dual robotic cell to assemble face frames in order to eliminate the strenuous manual labor.

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Coolant Reservoir
Type:   Plastic Processing
Level of Automation:  High

Challenge
To design an automated hot plate welding system that lowers labor costs and increases part quality.

Solution
Hot plate welding system that assembles and tests reservoir bottles for radiator coolant.

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Vision Guided Robotics - Flex Feed
Type:   Metal Processing
Level of Automation:  High

Challenge
Vision Guided Robotic Flexible Feeding allows for almost endless product line variations, eliminating the need for part-designated in-feed systems and machines.

Solution
JR can integrate flex feeding systems into assembly lines, stand-alone machines, and as upgrades to existing equipment, for any industry.

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Automated Barcode System
Type:   Other
Level of Automation:  High

Challenge
To create a barcode applicator, test, and packaging machine to replace multiple manual machines. The solution must offer control for speed and for handling multiple part types, and increase the overall speed of the process from 1 to 6 parts per second, depending on part size and shape.

Solution
This high capacity, low labor solution begins with a large, centrifugally fed bowl with adjustable speeds and adjustable and interchangeable tooling, capable of feeding an unlimited number of part types within a specific size range.

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