REAL Controls provides turn-key machine design and fabrication services for new manufacturing processes or upgrades to existing machines. We work closely with our clients to define the operating and performance requirements for each system. Then we develop the conceptual design of the machine using 3D CADD software. Once the client is satisfied with the concept, we develop a complete design package for the mechanical, structural and electrical systems needed for the machine. While the machine is being fabricated, we develop the software needed to run the machine. We support all phases of the development from conceptual design through installation, commissioning and training.

At the completion of the project, we provide our clients with complete design documentation including the design drawings and all software source code. While we appreciate follow-on work from our clients, we always provide the option for them to modify our system using the services of other engineering firms if they want to.

High Voltage Testing Machine

REAL Controls developed a high voltage testing system complete with all the components required for autonomous operation of the machine. The machine applies a voltage of up to 20,000 volts across a rubber material. If no current flows through the material, then the next section of material is automatically tested.  Once the entire roll of material has been tested, the machine automatically stops and a report is generated with the test results.

Winding Machines

REAL Controls designed, fabricated, programmed and commissioned a pair of winding machines for a client that manufactures rubber matting. The machines are synchronized to transfer the material from one winder to the other in either direction. The pair are mechanically identical and both can be operated from the control panels that are located on each winder. The pair can also be automatically controlled from a remotely located master controller.