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C & T Tool and Machine Inc. Projects

At C & T Tool, we are committed to providing innovative solutions for a range of applications. Below you will find a cross-section of recently completed projects:

Automated Projects

Expanding Arbor:
This was a rebuild of an existing expanding arbor that is used to clamp the ID of rotor laminations. The new expanding arbor was designed to clamp on two different sizes of rotors with inter-changeable plates for the different ID's.

Drilling Machine:
This fully automated machine is designed to counter bore 12 holes in a brake pad automatically. It can load up to 25 break pads in the loading deck, after that they are automatically loaded into the drilling area where the holes are drilled and then it is shuffled out the back of the machine where they are then unloaded.

Leak Test Station:
The leak test station was designed to automatically do a leak test on 2 left hand and right hand assemblies. It is a 4 station rotary table that has a separate nest for each headlight. There are 6 cylinders that come down on each station to seal up the light housing openings, it then proceeds to station 2 where the leak test starts and continues on all the way until station 4, where the data is calculated and determined whether it has passed. There are two cylinders at station 4 where there mark the part whether is passed or failed. The part is then indexed to the first station where it is unloaded and replaced by a new part.

Motor Assembly Stand:
The assembly stand is used to assemble an AC Traction motor, it allows the 6000lb motor to be manipulated in many different ways to help make safe and an easier assembly for the operator.

Paint Line:
These paint line arms were designed with a 5 to 1 safety factor to move the different models thru the paint line. There are fastening bolts on the end of the hangers to lock the rotors in place.

Pneumatic Brushing Press:
The pneumatic bushing press was designed to push many different bushing in several different armatures of landing gear. Variable forces can be used to push in the many different bushing.

Shaft Press:
An eighty Ton press that automatically presses in a rotor shaft into the rotor body. This is a specially design hydraulic system as it has to quickly put the shaft in the rotor before the expanded rotor shrinks and does not allow the shaft to be pressed into place. All the latest press standards were used to upgrade this machine to today's standards.

Stud Press:
The LX Bracket assembly station has the ability to press 2 studs into 2 separate assemblies. Part # Z800LX08A01 or # Z800LX08B01 are loaded onto table nests and the studs are pressed to desired tonnage. If parts are determined by operator to be incorrect an optional destruction of part is performed by means of a separate cycle start.

Brazing Tower:
The purpose of the Brazing tower is to manipulate the brazing tooling around so the operator can easily braze the AC Traction Rotor. The brazing tower rotates the brazing tooling around 360 degrees with a foot pedal allowing the operator to braze the bottom of the rotor. To flip the rotor around 180 degrees to do the opposite the brazing tower comes into the brazing table and picks up the rotor assembly, rotates it, and lowers it back onto the table. When the second end of the rotor is brazed it will again get picked up off the table where it will place it over the cooling tank and lower it in to cool the brazed end it will also rotate it around 180 degrees and dip the opposite end in cooling tank as well.

Cement Clamp Press:
The Clamp and Cement Press is designed to shape, press and heat two different commutating field coils. These coils are located in specially designed holding fixtures that are loaded into an opening on the right hand side of the machine. They are then driven into the press zone against a hard stop and shaped with pneumatically operated side and end presses. Once shaped the coils are pressed in the vertical direction with 30 tons of force with an air over oil cylinder and heated by passing an electric current through the coil.

Swage Press:
The purpose of the Swage Press is too press or swage the rotor so that the rotor shaft is dimpled in place. GEB26, GEB30, GEB 13, GEB27, GEB25A, and GEB25B can be swaged on the press. The rotor is manually loaded onto the rotor carriage and then the swage press automatically rotates and swages the rotor

Heat Press:
The Coil Heat Press is designed to form a variety of 'bobbins' to a specific thickness and width. There are two different styles of bobbins that are produced, racetrack and trapezoidal style, with varying dimensions and the machine is capable of processing them all. The bobbins are loaded onto one of the two parts trays and pushed into position under the heating platen. A lower press then moves the inside section of the part tray, which supports the bobbins, and presses the bobbins against the heating platen.

Core Press:
The purpose of the Core Press is to align the Core Motor lamination stacks in the load position. The table then moves to the press position and the press is then started for the style of motor that has been loaded. The press is started until proper pressing pressure has been reached. The operator then tightens the clamping rods then releases the press. The motor is then moved to the loading position and removed.

NLG Test Rig:
The purpose of the NLG Shock Strut Test Rig is to test the pressure of the Shock Strut after it has been fully charged with nitrogen and oil. There is a sequence of tests (ATP) that will be performed that are documented for each assembled Shock Strut.

Torque Reaction Arm (Patent Pending)
The Torque Reaction Arm serves two main purposes:

  • Provide ergonomic support to the operator by utilizing a zero weight condition while automatically absorbing torque to prevent potential repetitive strain injuries.
  • To provide positional info via sensors located on the arm (optional).

The arm size, overhead mounting and device mounting can be customized to suit any application.

Air Bag Door Assembly Fixture:
The Air Bag Door Assembly Fixture accomplishes two tasks. The first of which is to provide the operator with an ergonomic and stable work area to attach the Airbag Reinforcement Reaction Plate and Pal nuts. The second task accomplished is ensuring that the Airbag Reinforcement Reaction Plate has been applied and all Pal nuts have been installed to a specified torque before allowing the part to proceed through the assembly process. This is a highly customizable fixture and can be altered to suit many different applications and customer requirements.

Hummer 3 - Front Bumper Assembly Fixture:
The Hummer 3 Front Bumper Assembly Fixture is made up of two major components; a main build fixture and an overhead tooling frame. The main build fixture serves two purposes:

  • Provide the operator with a stable work area to hold the bumper components during the fastening process.
  • To ensure that all required parts are consistently placed within tolerance, functioning as intended and fastened within specifications as per manufacturer's recommendation.

The overhead frame is used to control the assembly process of the bumper, ensuring that all required parts are in place, within tolerance, functioning as intended and fastened to the required specifications as per manufacturer's recommendation.

Hummer 3 - Rear Bumper Assembly Fixture:
The Hummer 3 Rear Bumper Assembly Fixture is made up of two major components; a main build fixture and an overhead tooling frame. The main build fixture serves three main purposes:

  • Provide the operator with a stable work area to hold the bumper components during the fastening process.
  • To ensure that all required parts are consistently placed within tolerance, functioning as intended and fastened within specifications as per manufacturer's recommendation.
  • Ensure that the plastic step pad is pressed onto the shell effortlessly and consistently each time.

The overhead frame is used to house the controls for the fixture, the torque monitoring equipment and the torque reaction arms for the M10 & M12 fasteners. The torque reaction arms are designed to allow the operator to easily access the heads of the bolts and prevent injury to operator due to the torque applied by the screw gun.

Hummer 3 - Shell Clip Assembly:
The Hummer 3 Front Shell Clip Assembly machine has two functions, attach all the required clips onto the shell and attach two tow hook brackets. The clips are manually loaded into holders, which are then (when the light curtain is cleared) pushed onto the bumper shell. Prior to activation or removal of the bumper shell, clips are sensed both in the clip holder and on the part to ensure proper clip size on the proper location of the bumper shell. The second function of the machine is to attach two tow hook brackets to the bumper shell. Using Atlas Copco screw guns and monitoring tools that are mounted on slide units; the operator manually places two screws onto the screw guns. With the light curtain cleared and two sensors to make sure the screws are present the guns automatically move forward attaching the screws to the tow hooks while ensuring the bolts are fastened to the correct torque and rotation.

Hummer 3 - Side Bracket Clip Assembly:
The H3 Strap Clip Assembly machine's function is to attach all the required clips onto the brackets. The operator loads the clips into the holders and places the brackets onto the appropriate nest. When the light curtain is cleared the pre-loaded holders push the clips onto the parts. Clips are sensed both in the holder and on the parts to ensure that no parts leave the nest prior to having the proper clips in place.

Hummer 3 - Strap Clip Assembly Fixture:
The H3 Strap Clip Assembly machine's function is to attach all the required clips onto the brackets. The operator loads the clips into the holders and places the brackets onto the appropriate nest. When the light curtain is cleared the pre-loaded holders push the clips onto the parts. Clips are sensed both in the holder and on the parts to ensure that no parts leave the nest prior to having the proper clips in place.

Hummer 3 - Front Fascia Assembly Fixture:
There are two main functions of this machine. The first of which is to provide a stable work area for the operator that fixtures the parts to create a finished assembly within tolerance. The second function of the machine is to ensure that all parts have been installed on the assembly and fastened to their correct torque value. These parts are as follows:

  • Front Fascia
  • Plastic Reinforcement
  • Fog Lamps (2)
  • Metal Straps (3)
  • Front Grill
  • Plastic Seals

The machine monitors that all fasteners have been installed and to their proper torque with Atlas Copco torque monitoring equipment. These tools are hung from balancers for operator comfort and ease of use.

Heat Transfer Systems:
We are a global leader in the design and manufacture of fully integrated heat transfer systems and associated electrical control panels. Our equipment is successfully being used in some of the most technologically advanced hydro generation plants in the world. The experience we have accumulated serving the hydro generation industry qualifies us to provide clients worldwide with the highest quality equipment and services. Please take a moment to explore our online brochure.

Eccofloat Press & Wiper:
The Eccofloat Press & Wiper Assembly is used to glue and press the Eccofloat Disc to the Sitrans Probe LU Driver. This machine utilizes a custom epoxy dispenser to apply the epoxy, a pneumatic cylinder to press the Disc onto the driver, and a DC motor to rotate the two parts while a retractable wiper spreads the epoxy over the surface of the Driver.

Hotplate Weld Fixture:
The Hot Plate Welder is used to weld polypropylene rod antennas required for radar units. The semi-automated machine utilizes a heater to melt the ends that are being welded and a press that precisely welds the pieces together so that the overall length and eccentricity of the assembly is within customer specifications.

DR06 Front Bumper Assembly Fixture:
There are seven different part numbers that can be assembled on the DR06 Front Bumper Assembly Fixture and five different part numbers that can be assembled on the non-Heavy Duty Fixture. The machine is made up of three major components; a main building nest, an overhead tooling frame and a staging area. The main build fixture serves two purposes:

  • To provide the operator with a stable work area that holds the bumper components in place while they are fastened together.
  • To control the assembly process of the selected bumper and ensure that all required parts are in place, within tolerance, functioning as intended and fastened to the required specifications.

The overhead tooling frame houses all the controls for the fixture which include, the torque monitoring equipment for the M12 & M6 fasteners, the torque reaction arms for the M12 screw guns and tool balancers for the M6 screw guns. The staging area provides an initial nesting location for the bumper to be placed and work to be performed prior to being placed on the main building nest.

2006XK Rear Fascia Checking Fixture:
The 2006 XK Rear Fascia Inspection Fixture accomplishes three main functions:

  • To ensure that all required parts (as per bar code instruction) are in place and held together properly with their respective clips and pushpins.
  • Colour verification utilizing Four (4) DVT colour cameras to ensure the RPA sensor colour matches the colour of the fascia. The DVT cameras also check to see that the colour of the fascia matches the colour as identified by the scanned bar code.
  • RPA sensor test. Four RPA sensors are checked to be in working order with the use of a Bosch testing unit and respective software.

If all three tests pass the machine releases the part from the fixture and prints a "Pass" label which the operator applies to the underside of the bumper. Failure of any of the tests will result in the fixture holding the bumper in place until a floor Supervisor over rides the system.

Dodge LX Defroster Clip Assembly:
The Dodge LX Defroster Clip Assembly Fixture accomplishes three tasks:

  • Check that the part has had the foam attached around the ventilation louvers on the underside of the part.
  • Link the bar-coding system (Blackhawk) to the absence or presence of the sun sensor hole and the part's colour; this creates an identity for the part once run through the fixture.
  • Ensure that the metal clips have been properly attached to the stanchions of the part before the part is allowed to exit the fixture.

Hot Melt Glue Press:
The Hot Melt Glue Press utilizes a 3M Polygun II™ adhesive applicator to dispense the glue and a pneumatic cylinder to press a Driver into a Cap. There are two modes; automatic and manual. In automatic mode the fixture glues and presses the two parts together with a set amount of glue in the required sequence. The manual mode is used only to calibrate the glue gun and dispense glue manually.

Automated Welding Fixture:
This fully automated machine welds in end caps for various OD's and lengths of conveyor pipe. The machine also loads and unloads the pipe from the machine automatically.

Degate Press:
This fully automatic press was designed to easily remove gate tabs generated in the casting process from an aluminum ring seal, which is adjustable to 12 different ring sizes.

Stator / Shell Press / Welder:
The purpose of this machine is to press a fully wound stator core into a motor shell, and plug weld the assembly in four locations, 90° apart. This machine is fully automatic after loading

Multiple Tasks:
C & T is capable of multiple projects. Our facility allows us to build and test several units at one time, full assembly line fixturing and complete project tooling.

Automated Staking Machine:
This large unit stakes turbine wheels to keep the spacers and blades in place. Fully automated, all the operator has to do is load the turbine onto the machine and then the machine takes over from there.

Electrical Panels:
C & T designs, builds and programs the machines we build as well as custom panels for our customers.

Waterjet Buck:
Fixtures that hold dashboards properly in place as a waterknife trims the instrument panel. Several clamping devices are used to hold the dashboard properly in place with limit feed back.

Magnetic Particle Manipulator:
The MPM is a very large machine that has the capability to hold one turbine shaft or wheel at a time. Once the shaft or wheel has been loaded they can then be rotated by the MPM. While rotating there is a drop down tooling that comes over the machine to do the magnetic particle test.

Assembly Fixtures:
Multiple fixtures for assembling dashboards allowing the operator to rotate the dashboard around in order to assemble all the components. The fixture also works on a poke-yoke and continuous quality control exceeding dimensional tolerances.

Unwound Core Press:
The press automatically presses a shaft into the stator core to proper depth. Laminations are held under force, confirmed height and precision placement of the shaft.

Vertical Die Casting Machine:
This machine cast's aluminum fan blades for small motor rotors in a vertical orientation. It is fully automated and can provide up to 96 tons of clamping force, and perform tooling change outs with the push of a button. It is a re-build of a 1950's version and was brought up to 2000 standards incorporating automation and safety.

Explosion Proof Motor Manipulator:
Designed so the operator can effectively position and work on the motor, and pour an explosion proof liquid into the frame with ease. While tightly clamped, the manipulator rotates the motor and frame around 360 degrees, and tips back 45 degrees.

Clip and Degate Fixture:
The Clip and Degate Fixture has two main purposes; one is to insert clips onto extrusions on a plastic seat cover and the second is to degate the part. The machine is customizable for many applications whether it be a plastic seat cover or any other object which requires clipping. The object is clamped down onto a nest using hand clamps. The clips are pushed up onto the surface by pneumatic cylinders. When the clips are in place, another pneumatic cylinder pushes a sharp edge down onto the part removing excess material, or "degating" it.

Hybrid Hydrostatic Pressure Tester:
The Hybrid Hydrostatic Pressure Tester can provide water based pressure testing for a variety of customizable applications, it works in conjunction with a PLC to detect leakage. The machine also has the ability to perform its test for a wide range of pressures and part sizes with extremely accurate results.

Tie Rod Casting Machine:
Essentially the Tie Rod Casting Machine is an assembly of smaller machines working in conjunction to accomplish a single task. The machine consists of a robot to take the parts from the feeders to the casting station, the trimming station and eventually to the exit bin. This is a very fast machine able to churn out two parts every twenty seconds and is highly customizable for different tasks as requested by the customer.

Rubber Grommet Assembly Fixture:
The Rubber Grommet Assembly Fixture accomplishes three main functions. The first is to press two rubber grommets onto a plastic part so that it is properly locked in place by tabs on the plastic part. The second function performed is the product verification, which is done by utilizing a camera to ensure the grommets were installed correctly. The third function is the ejection unit which monitors the quantity being ejected from the machine to guarantee that the correct box quantities are packaged. There is a rotary indexing table with four nests which shuttles the part from station to station ensuring the necessary cycle time is met.

Weldment projects

Roller Table:
This table allows an operator to rotate a 6000lb rotor around 360 degrees by hand and then stop it where ever they want so they can sand blast the motor properly.

Roll Bake:
Designed to clamp the 5000 lb motor frame and stator assembly in the center of the fixture and balance it concentrically. A swing arm swings out and allows the motor frame to be dropped into the fixture; it is then swung back and pinned in place thus locking the motor in the roll bake fixture. It is then moved into a 500 degrees oven and the resin is baked onto the motor frame.

Assembly Cart:
This cart was designed to hold the landing gear on the movable table with the ability to swivel 360 deg and pivot to the upright position to allow the operators to load it into a test area.

Cycling Assembly fixture:
This fixture is used to mate a landing gears cylinder and piston. It also houses the gear while additional parts are being assembled onto the gear. The bottom swivels 180 deg to allow the operator to check the swivel action of the axle.

Specialized Carts:
C & T Tool has designed many specialized carts for the auto, motor, and plane industries.

Rotor Lamination Lifting Device:
This lifting device is used to move the Assembled Laminations from station to station.