From initial contact to final installation

(See Torus Modular Frameworks at MachineBuilding.Live, 2 October 2024, on stand 40)

The client was looking to update what they were finding to be an outdated and restrictive machine, and Torus Modular Frameworks was able to offer an alternative with the capabilities to fully meet requirements of the present and future.

Though the existing machine was still functioning, it offered no ability for growth or variation on testing.

After a consultation in person with the Torus Modular Frameworks sales team, a specification for the needs and requirements of the client was passed on to design for a bespoke watertight structure to be conceived. The specification required the enclosure to fully utilise the designated area for the machine, allowing a level of testing previously unobtainable.

The solution conceived for this client entailed a large structure with a XYZ gantry system, fully programmable to their varying requirements. It also had to be watertight allowing the recycling of liquid fully contained within the sump tray.

Design process

Once the project was passed to design, the specification was reviewed and a model created. This was then passed to the client for them to evaluate, discuss and request changes they required.

The finalised design consisted of three individual trays all draining into a single sump tray with dual sump pumps recirculating the chlorinated water back to the spray nozzle. This method was used due to access restrictions to the finalised location but still achieving the necessary requirements outlined by the client. Aluminium panels were used to direct water back into the drainage system to reduce the use of materials such as silicone. Such actions are taken to decrease the frequency of maintenance needed to maintain the watertight seal and to prevent leaks.

The framework of the system all consisted of aluminium extruded profiles connected with an easy to adjust but strong connector, simply adjusted with a 6mm hex key. Considerations were taken to ensure all connections and connectors could withstand the high humidity environment. Due to the presence of water, a fully custom GRP anti-slip grated floor was commissioned that had the capabilities to be easily removed should the customer require access to the drainage system beneath.

Manufacturing

Torus Modular Frameworks' in-house machine shop consisting of a CNC router, milling machines and various other machines allows the company's skilled production team to take in-house 3D CAD models right the way through to installation. All materials relating to the framework and panelling are prepared in house, allowing for a streamlined manufacturing process.

With the aforementioned project, using Torus Modular Frameworks' in-house machine shop the framework went through various processes of cutting and milling, giving a final visual effect of heavy duty and robust but not excessively dominating. With the CNC router the operator could accurately cut the black aluminium composite panels creating a sleek and clean finish with any adjustments required being easily implemented.

Upon delivery of the drainage system, it was built and contained within the aluminium extrusion framework, allowing the final installation of the project to create less disruption and require less installation time on the customers premises.

Once the framework was completed and the XYZ gantry system fitted, the whole system went through an extensive validation process ensuring its watertight design and client's requirements were completely met. Within the validation process the customer was invited to visit to view the finished product allowing any final feedback prior to the installation on their premises.

Installation

Installation of the project consisted of members of the Torus Modular Frameworks team, both loading and unloading the frameworks from dedicated transport, on pallets built and designed specifically to keep our products safe in transit.

Torus Modular Frameworks' experienced team carried out the install ensuring the customer was well advised on the next steps of the build as and when they progressed. On completion, demonstrations of the function of the system were provided allowing a seamless handover - thus giving the customer all information required for the use of the machine, with Torus group but a phone call away for any support they may require.