Complete Portfolio

Manure Solid and Liquid Separator

The manure solid liquid separator is used to manage manure problems, such as odor, run-off, soil compaction, and environmental liability.  We were able to work with the OEM to get their ideas into a drawing package ready for manufacturing.

Auto Clean Screen

The auto clean screen allows treated liquids to be safely drawn from the aerated zone of the treatment basin as part of a manure managing process.  We were able to work with the OEM to get their ideas into a drawing package ready for manufacturing.

Hydraulic and Pneumatic Diagrams

Design of new equipment or upgrading of vintage machinery often involves incorporating fluid control.  We are capable of the design and documenting of hydraulic and pneumatic systems.  We also have very close ties to an electrical control company who we often call upon for support.

Excavation Roadheader Sales Proposal

For a sales proposal, the customer required a 3D model of the machine to check for spatial issues at the intended work site.

Blast Machine Rendering

Blast machine model was built using 2D drawings from existing machines.  Three dimensional images were then created be used in sales literature.

Blast Wheel and Fender Renderings

Blast wheel and fender models were built using 2D drawings from an existing machine.  Three dimensional images were then created be used in sales literature.

Documentation for Agricultural Literature

The manure separator was reversed engineered and a complete drawing package created.  We then did documentation that is used on our customers sales literature and web site.

Duct Work Layout

Pollution control system designed for a plant producing cement and concrete products.

Duct Work Layout

Pollution control system designed for a using a chemical coating process.

Platform Layout for Air Ventilation Unit

Pollution control system and structural platform designed for a plant producing cement and concrete products.

Deck Weld Fixture

Tack welding carts designed to be part of a flatbed tow truck assembly line.  Each cart has multiple sets of tooling to accommodate various deck sizes and styles.  One end of the shorter cart has the ability to tilt down several degrees allowing assembly of a dual-angle deck.

Boom Tack Welding Fixture

Tack welding fixture designed to handle 3 different booms with no tooling changeover.  Subassemblies are positioned and clamped on the fixture then a welder tacks components in place.  After fixture was assembled at our facility a complete laser inspection is done to certify critical positions. The fixture was designed to hold the locating items within +/-.006".

Hydraulic Clamping Boom Tack Welding Fixture

Tack welding fixture designed to handle 2 different booms with no tooling changeover.  Subassemblies are positioned and clamped on the fixture then a welder tacks components in place.  After fixture was assembled at our facility a complete laser inspection is done to certify critical positions. Due to the extreme size and weight of the boom parts, hydraulic cylinders were used to push and clamp boom and loose pieces together.  The fixture was designed to hold the locating items within +/-.006".

Frame Tack Welding Fixture

Tack welding fixture designed to handle 3 different frames with no tooling changeover.  Individual plates are positioned and clamped on the fixture then a welder tacks components in place.  After fixture was assembled at our facility a complete laser inspection is done to certify critical positions. The fixture was designed to hold the locating items within +/-.006".

Modular Table Weld Fixture

Modular fixture was designed with a four section table and has the capability of adding additional sections as required.  A pattern of mounting holes in the table sections allow tooling components to be mounted anywhere along the length of the table.  Tooling components were designed to accommodate a large range of parts allowing adaptability for future products.

Heat Shield Hat Clip Weld Fixture

Fixture positions and clamps a heat shield and two hat clips using pneumatic slides and magnets.  Parts are then spot welded in position.  This process is used in a local motorcycle manufacturing facility.

Mandrel for Automatic Welder

Mandrel is pulled through four sheets of steel accurately positioning them during an automatic boom welding process.  The 3D design was developed to allow the engineer to change the cross section of the boom then those dimensions drive the mandrel design.  This makes the engineer very efficient when creating mandrels for other size boom sections.

Lay-on Tack Welding Fixture

Tack welding fixture designed to handle 2 different booms with no tooling changeover.  The fixture locates the nose weldment and the cylinder attach plates relative to the end of the boom within +/-.006".  After fixture was assembled at our facility a complete laser inspection is done to certify critical positions. no tooling change-over.  The fixture locates the nose weldment and the cylinder attach plates relative to the end of the boom within +/-.006".

Apply Lay-on Tack Welding Fixture

Lay-on tack welding fixtures developed to accurately and consistently place components for tack welding.  Fixtures must allow ease of access for tack welding component and be light weight to meet manufactures lifting requirements.

Apply Tools for Tack Welding

Lay-on tack welding fixtures developed to accurately and consistently place components for tack welding.  Fixtures must allow ease of access for tack welding component and be light weight to meet manufactures lifting requirements.

Door Router Fixture

Large door and window manufacture requested the design and build of a fixture that would allow them to route hinge mortises consistently.  The fixture had to be capable of accepting multiple heights, widths and thickness along with both left and right hand doors. WDSI designed and detailed a complete package along with ordering parts and managing the assembly.  The fixture had pneumatic clamping and a no tools required changeover.

Machining Fixture

Machining fixture designed to accurately and rigidly hold a large weldment in a vertical position during a machining operation.

AGFM Insert Checker

Fixture designed to hold an AGFM cutter head in a vertical position to ease replacement of cutter insert.  The cutter head is bolted to the fixture and rotated by a stepper motor using a hand wheel control.  After all the cutter teeth have been replaced, the gage arm is placed into position.  A dial indicator is used to check the height difference from tooth to tooth within .0001 inches.

Controller Response Checker

Fixture was designed to accurately position the joystick controller.  This allows the joystick to be tilted in any direction to verify that it responds at the correct degree of movement.

Deck Rollover Weld Fixture

Rollover weld fixture designed to securely hold flatbed decks to complete the welding process.  The fixture centers and clamps onto I-beams on the underside of the decks.

Roll-Over Welding Fixture

Welding fixture designed to handle 2 different axle boxes (about 1600 lbs each) with no tooling changeover.  The fixture holds the axle box off the floor for complete welding access.  A hand wheel attached to a worm gear is used to rotate the axle box to any angle for welding.  The rotation can be locked in at 90-degree increments.

Drive Sprocket Assembly Fixture

Assembly fixture is mounted to a purchased roll over unit and holds a drive sprocket in position during an assembly process allowing the operator to complete the full assembly without manually manipulating the part creating a more efficient and safe working environment.

Door Roll-Over Assembly Fixture

Fixture incorporates bearings and a gearbox to allow an operator to roll the part over while it is held in position during an assembly process.  This allows the operator to complete the full assembly without manually manipulating the part creating a more efficient and safe working environment.

Frame Roll-Over Welding Fixture

Fixture designed to hold a lift frame during a final weld operation.  Frame can be rotated then locked into positions at 90 degree increments allowing operator to always be able to do a horizontal weld.  Weights were calculated to properly place the center of gravity to make rotating the part safe and easy.

Gas Series

Local grill manufacture had a full product line with no documentation.   WDSI measured all components, made recommendations for modifications and did a the complete drawing package.

Griddle Series

Local grill manufacture had a full product line with no documentation.   WDSI measured all components, made recommendations for modifications and did a the complete drawing package.

Charcoal Series

Local grill manufacture had a full product line with no documentation.   WDSI measured all components, made recommendations for modifications and did a the complete drawing package.

Trailer Series

Local grill manufacture had a full product line with no documentation.   WDSI measured all components, made recommendations for modifications and did a the complete drawing package.

Tailgate Series

Local grill manufacture had a full product line with no documentation.   WDSI measured all components, made recommendations for modifications and did a the complete drawing package.  After existing grill was documented we began redesigning the grill to reduce weight and cut manufacturing cost.

Side Panel Lifting Device

Lifting device was designed to allow an overhead crane to pick up the side panel for a truck body.  The panel is originally laying flat and must be lifted to a vertical orientation.

Turret Lifting Device

Lifting device is used to lift a turret from a horizontal position to a vertical position and placed onto a machining fixture.  Calculations were done to determine the center of gravity so the lifting ring could be placed in the proper position for ease of installation to the fixture.

Camshaft Polisher Chucks

Chucks were designed to hold different camshaft work parts while being polished.  The camshaft is positioned by a spring-loaded center then clamped with a collet that is driven by a spring/air piston.

Machine Mist Enclosure

WDSI has designed complete watertight enclosures for the machine tool industry.  We have worked closely with sheet metal manufactures to optimize the design with manufacturing as a primary concern.  Enclosures typically have sliding or hinged front/loader doors with safety interlocks.  Also lift off panels are strategically placed to allow easy access for servicing the machines.

Machine Tooling

Retrofit and retool packages for the machine tool industry is a specialty of ours.  We have years of experience in developing tooling for new equipment and retooling used equipment for new processes for OEM parts.

Retro-Fit Machine Tooling

Retrofit and retool packages for the machine tool industry is a specialty of ours.  We have done designs to retrofit ballscrews and CNC control dressers into older vintage machines. Also we have taken the lead on complete rebuilds and retools of used machinery.

Grinding Machine Wheel Feed Upgrade

The wheel feed on a grinding machine was upgraded by replacing the stepping motor system with a Fanuc servo drive system.

Grinding Machine Wheel Feed Upgrade (2)

The wheel feed on a grinding machine was upgraded by replacing the stepping motor system with a Fanuc servo drive system

Landis Ballscrew Retro-Fit for Wheel Feed

Design was completed to change the wheel head feed from a stepping motor with ACME screw to a CNC controlled servo motor with a precision ball screw.

Dresser Retro-Fit for Grinding Wheel

Design was completed to replace a hydraulic infeed dresser with a servo motor and ball screw infeed dresser which included a rotary plunge head with VF drive.

Workrest Retro-Fit for Grinding Machine

Workrest was designed to clamp on an existing grinding machine table and support work part during precision grind operation.

Rack and Pinion Drive Retro-Fit for a Boom Welder

A hydraulic cylinder originally drove the boom welder table.  We removed the cylinder and replaced it with a rack and pinion servo drive system.  This allowed the speed of the welder table to be controlled and reduced the jerkiness caused by the inconsistent pressure in the cylinder.

Rack and Pinion Drive Retro-Fit for a Boom Welder

A push pull chain originally drove the boom welder gantry.  We removed the push pull chain and replaced it with a rack and pinion servo drive system.  A servo drive system was mounted on each side of the gantry.  This allowed the speed of the welder gantry to be controlled and reduced the jerkiness caused by the push pull chain.

Centerless Grinder Rebuild

Centerless grinder retooled to grind larger shafts.  A complete layout of the foundation, bed, tooling, gauging, dresser, and motor control was included as part of necessary design changes - intended to match an existing machine.

Test Stand Upgrade

A test stand required redesign of plumbing and electronics to test a different pump. Bench tooling needed to disassemble and rebuild the new pump was designed for use in an overhaul room

Vertical Floturn Upgrade

The control of the machine was upgraded from relay style to PLC style. All hydraulic equipment was either overhauled or replaced.

Grinding Wheel Guard Upgrade

To meet safety standards, wheel guards were redesigned to provide better wheel coverage but still be accessible for maintenance.

Excello Retool – Crankshaft Radial Orientation Hole

Retrofit and retool packages for the machine tool industry is a specialty of ours.  We have years of experience in developing tooling for new equipment and retooling used equipment for new processes or OEM parts.

Cam Shaft Grinder Retool

This machine was shipped to our facility where it was rebuilt and retooled to grind a new cam shaft.  The tooling was redesigned to accommodate all of the features for the new shaft.

Machine Loader

Retrofit and retool packages for the machine tool industry is a specialty of ours.  We have years of experience in developing tooling for new equipment and retooling used equipment for new processes or OEM parts.

Jack Stand and Air Float System

Air float system was designed to carry several different crane frames through an assembly line.  The unit uses four air floats between two separate stands with air lines connect through a hose reel.  System allows an individual to manipulate several tons without assistance.

Turning Rings

Turning rings were designed to carry a load of approximately 80,000 lb.  Originally the part was turned using an overhead crane and lifting slings which is time consuming and dangerous with such large parts.  The rings allow the operator to rotate the part to any orientation safely and in a matter of minutes.

Robotic Arm End Effector

Robotic arm to lift tubing needed to be redesigned from a magnetic end effector to one that clamped.  The arm inserts the effector into one of the stacked tubes and clamps to the outside before lifting.

Sub Frame Cart for Blasting and Paint

A universal cart was designed to hold sub frame weldments through both the blasting and paint process.  Previously, several carts were used to hold specific sub frame lengths or styles.  To reduce time waiting on availability of particular carts, they were combined into one capable of holding many different sub frames.

Weldment Kit Racks and Work Station

8 ft. and 12 ft. long racks were designed to hold weldment kits for transportation between facilities and use on the assembly line.  The kits are are transported to the work cell, stacked, and unloaded to a table as they are ready to be welded.

Carrier Build & Storage Cart

Final painted parts for carrier frames are assembled on this cart.  The integrated rack allows the finished frame to be lifted off the cart, stacked and stored until it is needed for assembly with the vehicle.

Tow Line Cart

This cart was designed for use on a new assembly line.  The pinned supports can be placed in different height and width positions to accommodate a wide range of vehicle sizes.

Clamping Fixture with Drying Rack

This fixture was designed to position and clamp foil insulation packs to steel door panels during gluing process.  After components are glued and clamped they can be hung in the drying rack to cure.  This process was developed to make assembly placement consistent and free up floor space required during 10 hour curing time.

Robotic Material Handling Arm

Conceptual sketches of a complete material handling system were developed to manipulate rubber-roofing materials.  System was designed to eliminate injuries related to lifting of heavy rubber roofing materials.  From the sketches the design and detailing of robotic arm was competed, parts ordered and assembly managed.  We worked close with the material manufacture and electrical engineers to verify that all aspects of the project had been considered.

Frame Kit Racks

Racks are used to group all of the components required to build a vehicle frame into a kit.  The racks can then be delivered to the welding cell for assembly.

Cab Racks

Racks are used to mount a completed tractor cab for shipping and transportation in assembly plant.

Engine Stand

Stand was developed to mount two different incoming engines to for ease of assembling additional components and transport through facility.

Suspension Arm Install Devise

Hydraulic pump was replaced on a cart that holds up to 3 suspension arms in place for installation in a vehicle.  Guarding for the battery and pump were also included in the upgrade.

Track Install Machines

Carts with motorized spools of cable to pull tracks over vehicles were reverse engineered and upgraded.  They attached to the front of the vehicles which together rolled forward as the tracks were pulled over suspension arms.  A different machine was used for each of 3 vehicles.  Mesh guarding was added for safety.

Line Transport Dollies

To eliminate using an overhead crane while moving between work stations, these transport dollies were designed to allow heavy frames to be rolled during the assembly process.  Two different dolly styles were produced to clamp to either a vertical plate or tubing at the bottom of three different vehicle models.

Spring Collapse Tool

This tool is used to collapse a large compression spring to aid in the installation in a vehicle.

Boom Turntable Upgrade

Crane turntable was upgraded to allow application of heaver load at low boom angles.  The entire turntable was raised, requiring a large spacer to be added between the chassis and the turntable bearing. A second motor was added as well as the ability to hydraulically lock the turntable.  This required 4 ports to be added to the swivel assembly at the center.  Updates to hydraulic and electrical diagrams were included as part of the final drawing package.

25,000 lb Load Capacity Sawhorse

Sawhorse was designed to carry a 25,000 lb. maximum load for use in crane manufacturing.

Adjustable Seat

This seat was designed to be used in an assembly line prior to the permanent seat being installed in a vehicle.  The design had to be light weight to allow ease in installation and removal along with handling capability of holding a 250 lb. person during typical driving conditions.

Boom Counter-Weight Platform

Platform is used in assembling and aligning multiple boom sections for a crane manufacture.

Boom Support

Support is used in assembling and aligning multiple boom sections for a crane manufacture.  This unit has wheels which sit on floor mounted rails.  It also has a self contained hydraulic power unit which supplies power to two large cylinders for raising and lowering boom sections during assembly and alignment procedures.

Air Cleaner Cover Die Assembly

Original die design was done by a die manufacture.  Die assembly was then handed off to WDSI to make major modifications to fit it to OEM's equipment along with bringing it up to their  requirements.

Winch Tension Arm Spreader

This winch tension arm spreader is used to precisely open tension arms on a winch assembly so the limit switches can be safely and accurately set.

Hydraulic Cylinder

Cylinder design and reverse engineering for manufacturers of hydraulic cylinders used in products ranging from hydraulic dump beds and trailers to cranes and aerial work platforms. We have had involvement with Single Acting, Double Acting, Telescopic, Ram and Custom Designed Cylinders.

Muzzle Loader Quick Loader

Quick loader allows a rifleman to preload up to six shots and carry necessary gear for his muzzle loader in a convenient case.

Storage Cart

Cart was designed to allow easy maneuverability and storage for a process specific lifting device.

Boom Covers

Covers are used to close all openings in boom sections during shot blasting operation.  This saves operators from cleaning leftover shot from the inside of the boom and also decreases the amount of shot lost during the process.  All covers were designed to be quick release to limit both installation and removal time.

Milling Head Upgrade

Excavator milling head was reverse engineered and improved to reduce wear on the bearings.

Sub-arc Welder

A track system was designed for a sub-arc welder to attach to an existing fixture.  It's purpose is to weld the plates together on the hull of a vehicle.

Matrix Band Machine

High-speed machine for dental industry that makes the matrix band that is wrapped around your tooth while being filled.  3" wide stainless steel is feed through a progressive die at the rear of the machine.  The part is then transferred to the front units were a large conical loop is made, a lock loop is fastened to it to hold the shape, and 6 tight winds are placed at the other end of the part.  The finished part is transferred to a vision inspection station where it is determined a "good" or "bad" part.  A part is made every 3 seconds.  The machine was designed to make 4 different size matrix bands with minimum changeover.

Arial Lift Platform

New aerial lift platform design with automatic assist lift up front gate.  The customer came to us with the concept sketch.  WDSI developed the complete design / detail package then managed all aspects of the build for the first prototype.

4 Wheel Suspension for Arial Lift

New aerial lift suspension design keeps platform level as vehicle maneuvers through various types of terrain.  The customer came to us with a concept.  WDSI developed the complete design & detail package then managed.

Frame & Outriggers for Arial Lift

New frame and outriggers design for an aerial lift.  The customer came to us with the concept sketch.  WDSI developed the complete design / detail package then managed all aspects of the build for the first prototype.

Cylinder Assembly and Test Station

Machine designed to build, pressure test, cycle and clean hydraulic cylinders.  The piston is assembled onto the rod on the center section of the table.  The rod is assembled into the cylinder on either side of the table.  The one side of the table will be in the up position doing the pressure checks and cleaning cycles while another cylinder is being built on the opposite side of the table.  The station is designed to handle a wide range of cylinder types and lengths with minimum tooling changeover (no tools required).

Indexing Fixture Design Proposal

WDSI was approached with an idea for a new style of fixture indexing and asked to do conceptual design work and create views that could be presented during a formal design proposal meeting.

Engine Block Blast Cabinet Design Proposal

Blast machine manufacture had a concept for blasting engine blocks.  WDSI took the concept and developed it into a working model in order to prove out the proposal.

Vehicle Blast Cabinet Design Proposal

Blast machine manufacture had a concept for blasting vehicle bodies.  WDSI took the concept and developed it into a working model in order to prove out the proposal.

Vehicle Suspension Arm Install

Design concept of an assembly station to press bearings into the suspension arm, then transfer from a table into position for installation on the vehicle.

Auxiliary Rescue Units

Primary design source for Foster Rescue Products.  WDSI began work with Foster to reverse engineer their first emergency rescue unit.  Since the initial project we have played a part in the development of more than 6 new models and multiple versions of each model.  This is an ongoing project due to the highly specific and constantly changing requirements of each unit.

Dump Trailers

WDSI has been involved with several trailer manufactures.  We have completed reverse engineering and new design/detail projects on single and tandem axial trailers that have either solid or dump beds.  Also we have done consulting along with product cost analyzes and fixture design.

Exploded View and Parts List

WDSI reversed engineered and created the complete drawing package for the full line of grills.  Our customer then asked if we could create a easy to understand assembly and parts list that could be included with the product for customer assembly and part replacement.

Machine Tooling

Tooling is used in the automotive industry.  Locator radially orients the crankshaft.  Fixtures laterally locate, support and clamp the crankshaft during a grind operation.  We have years of experience in developing tooling for new equipment and retooling used equipment for new processes or OEM parts.

GRADER HI-LIFT KIT RACK

Container was developed to group all components for a sub-assembly on a motor grader line.  As components were received they are placed in the container and when full it is delivered to the assembly cell.  Parts are placed so the operator can pull each out in the order needed to build.

Frame Rollover

Weld tack fixture was developed to locate components of heavy construction vehicle frame.  Fixture was designed to be mount to a set of ALM positioners so it could be rolled over to be more ergonomic for welding.

Track Fixture

Two sided weld tack fixture was designed and built to locate components of a sub-assembly for boom lift vehicle.  Complete rollover was developed to save floor space and allow weld cell to quickly change between multiple components.

Pin Boring Fixture

Machine was designed and built to bore the A-Pin hole (boom pivot) on Telehandlers.  Design included mechanical, electrical and fluid control.  Tooling was developed to allow for quick changeover between multiple different Telehandler frames.

Roll-Over Fixture

Process and tooling was developed for a Telehandler assembly line.  There was difficulty installing components on the vehicle so this enabled the frame to be rotated to an ergonomic working position for employees.

Jerr-Dan Motoman

Fixture was designed and built to hold a full line of rollback decks in a Motoman weld cell.  Arms are able to be positioned via a hand wheel and tooling can easily be changed for different deck configurations.

HI-LIFT BLADE HYDRAULIC CYLINDERS LD009822

Lifting device was designed and built to assist during assembly.  Large heavy cylinder needed to be manipulated into proper orientation for installation on motor grader.  This fixture gave the ability to pick and position as required.  Project included FEA and PE stamped drawing based on a 3 times safety factor.