![Corporate Overview Presented by: Douglas Duesing, CFPS Sales Engineer, South Bend Controls e: [email_address] p: 574-532-9879](https://image.slidesharecdn.com/sbccorporateoverviewmay2009withnotes-12590908958048-phpapp02/85/South-Bend-Controls-Corporate-Overview-1-320.jpg)
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South Bend Controls Corporate Overview
- 1. Corporate Overview Presented by: Douglas Duesing, CFPS Sales Engineer, South Bend Controls e: [email_address] p: 574-532-9879
- 2. Quality Statement “ South Bend Controls will design, develop, manufacture and continuously improve quality products that meet our customers’ expectations in terms of value, delivery and performance.”
- 12. Revenue Distribution 40% 10% 20% 30%
- 21. Space Minuteman III Stage 3 Pressurization Package
- 30. Conclusions
Hinweis der Redaktion
- South Bend Controls was founded in 1940, and is a privately-held company headquartered in South Bend, IN, with revenues approaching $9M. It has always been owned by our parent company, Koontz-Wagner, that was recently purchased by a private equity group. SBC’s current facility occupies approximately 42,000 sq. ft. with 63 employees, and is located alongside the St. Joseph River.
- RJP – Brief history of the corporation. Koontz-Wagner, our parent company, is a privately-held diversified electrical company with annual revenues close to $80M, and is engaged in Manufacturing, Maintenance and Construction. It was established in 1921, and has seven facilities across South Bend, IN, Bryan and Lima, OH, and Knoxville, TN.
- Primary product line: Fluid Control Devices and System Integration, specializing in Solenoid Valves, Proportional Valves, Aerospace Regulators and Quick Disconnects Operation consists of: Design, Manufacturing, Final Assembly, Test Cells and R&D, Sales and Administrative. This operation gives us the ability to be completely autonomous from K-W, only sharing HR Resources, which allows us to be nimble and responsive to our customers.
- SBC’s strategy consists of three elements: Niche Marketing, Collaborative Engineering and Standard products. The first two, Niche Marketing and Collaborative Engineering are used most often with the Aerospace business segment; while the standard product is used for the commercial business segment. Because no two aerospace applications are the same, the products developed are typically very specific to that application and cannot be used elsewhere. In most cases, selling quantities of 100 to 1,000’s per year of an aerospace product is considered a ‘good size’ order. This requires a niche approach and extensive customization by collaborative engineering. The commercial business is very different, since the products are standard in a extremely price sensitive market. Typical orders are in the thousands to tens of thousands per year. The standardization is flexible and uses a simple part numbering system.
- Next, I would like to cover our market segments and customer base. Even though we at SBC measure our revenue in millions, we are a valued supplier to sophisticated customers that measure annual revenues in billions, thus we embrace their needs for stringent quality programs, documentation and continuous improvement. These Fortune 100 & beyond companies vary by segment, but include a wide variety within each market segment, and require different levels of sophistication and documentation demands.
- Now for some descriptions of SBC’s Markets, Products and Applications. Starting with Aerospace and defense: SBC develops and manufactures solenoid valves for applications like Engine Fuel Controls, Hot air control (for anti-ice of control surfaces), Emergency Slide & float inflation systems for the Boeing 7-5-7, Landing gear actuation and Flap actuation. SBC’s patented proportional solenoid valve technology –the Servoid- is used in Emergency Power Units to control air fuel mixture. The upper right picture is the Japanese F-2 aircraft (equivalent to a F-16) which uses the system. Because air density is limited at 35 thousand feet the system carries it’s own air supply which is metered along with the JP fuel to the combustion chamber by our Servoid valves. These tend to be very harsh environments (-40 degree fahrenheight, high vibration). In these applications the products must work every time. If the engine should flame out the pilot has 180 seconds to regain control and restart the engine. Another important application shown in the middle left picture is the fuel control (ott fuel and oxidizer) for the British spear fish torpedo. Again a critical application. An intriguing fact is that the oxidizer for the reaction with the propellant is seawater which is ingested and metered to the combustion chamber. SBC is relied on for both the fuel and seawater metering components.
- In the space segment, SBC supplies products which are used on the space station – ball valves and regulators on the Japanese Experimental Module, as well as applications on the Centaur, Atlas and former Titan Space craft – quick disconnects for loading propellants and liquids prior to launch, and also on the minute man missile – payload attitude control components – regulators, thrust control solenoid valves, pressure relief valves and squib. Additionally, over the last few years, SBC has been involved in the target vehicle for the development Missile Defense System -- SBC products position the target vehicle which simulates an incoming hostile warhead.
- Applications and products which are not associated with Aerospace or Space are called commercial products. These applications include the medical market in which the Servoid is used in Patient Ventilation, Anesthesia Delivery, Angiography and Laparoscopic Surgery. These applications are considered ‘life support’ and require impeccable reliability at a reasonable cost. Other applications within the medical segment of commercial product include inert valves which meter either aggressive liquids used in blood diagnostic equipment or kidney dialysis or blood products. These applications require that the flow paths within the system are inert – they do not contaminate the flow stream - and are able to withstand the harsh chemicals or heat used to clean the system to prevent cross contamination. Shown here is a Ventilator, blood analysis machine, dialysis machine and a slide prep machine used to automatically prepare tissue samples for the pathologist to examine.
- Other noteworthy aplications include ultra pure water dispensing and purification, and Power Generation and Fuel cell reformer fuel system components.
- As mentioned earlier SBC is self sufficient with the exception of HR functions. Engineering utilizes Pro/Engineer, AutoDesk Inventor, FEA, MFEA, FEMM and Data Acquisition. Tools List ESI CFD Cadalyzer (Stress and CFD Calculations) Autodesk Inventor 2008 Pro/Engineer Wildfire 4.0 HP Vee & LabView Data Acquisition FEMM 2-D Magnetic Modeling
- Manufacturing has Full Machining capability, C.N.C. Milling, turning, grinding and lapping and extensive use of SPC. Assembly has a class 100,000 clean room and perform special operations like brazing and coil winding, soldering and potting, on-site. For other assembly functions like plating and hardening, we use outside partners. The 42,000 square foot plant is divided into a separate office area, machine shop and assembly area.
- SBC’s quality system was Originally based on MIL-Q-9858A and has since been I.S.O. 9001 Registered and A.S. 9100 Certified by P.R.I. SBC is currently upgrading to I.S.O. 9001-2000 and A.S. 9100 Revision B. versions. SBC is also a certified FAA Repair Station, and is currently applying for EASA Supplement to be a certified Repair Station for European manufacturers. We test 100% of our valves prior to leaving the factory, and ensure we document traceability for all materials found in a given product. With these rigorous of quality standards, and our sophisticated customer base, we are often audited by our customers, averaging one audit per month; a process that we welcome, as it only helps both of us to continually improve and share best practices.
- The test capability includes full data acquisition , Flow Benches dedicated to: Stoddard solvent, Skydrol, Mil-H 5606 Hydraulic Oil and Water, Pneumatic stands Capable of 1000 O F and an Explosion Proof off-Temp Pneumatic and Stoddard Test Room. Having these test capabilities allows us to simulate application conditions in a laboratory environment, and is part of the Collaborative Engineering process of our strategy. Now we will take a look a SBC’s technologies.
- First, the Aerospace technologies. As mentioned earlier the aerospace products tend to be low volume and application specific. As shown in these pictures, the products are designed for a specific geometry and have specific functions. No two products are identical. In most cases 100 per year is a large order. These applications incorporate core technologies.
- SBC has been designing and manufacturing solenoid valves for over 60 years. These include 3-Way, 2-Way both soft and hard seat, ball and gate valves, Manifold surface or manifold insertion mount, Available in ESEOD’s up to 0.250 inches (C v = 1.125) they include Multiple coils for redundancy and handle Pressures up to 5000 psi.
- SBC designs and manufactures Quick Disconnects which Includes both ground and flight halves with incorporated lanyards – after use the section left on the launch pad is returned to have a new flight half mated to it and is reused - these units are affectionately referred to as blast and burn units. The quick disconnect are compatible with helium, liquid oxygen, hydrogen, and nitrogen and qualified to extreme operating temperature variations (-220°F to 300° F).
- Other products used in space applications are Regulators which are Single stage 4000psi to 280 psig Thrust Control Solenoid Valves, Pressure Relief Valves
- Finally “system solutions” which include a Variety of systems specific to the application and the customer’s specification. Typical systems include a Servoid, metering spool, and pressure regulator packages for precise control of fluids, while others include hydraulic solenoid actuated fuel spool valves. The value of combining these separate components into one body is immense, and ranges from reduction in assembly time, reduction in leakage, weight and size savings to the ability to order one p/n from one supplier.
- As we talked about earlier the commercial product is considered a standard product. As shown by these pictures the commercial product tends to be higher volume products compared to the Aerospace product. The use of plastic injection molded parts and encapsulated coils allows for relatively low cost. The only technology shared between the aerospace and commercial product lines in the Servoid shown in ht upper right corner. The other two valves are inert valves for clinical chemistry – the MIV and for kidney dialysis – the IDV.
- The MIV is a miniature inert valve where the flow path is isolated from the solenoid via a diaphragm. It’s features are as follows; 2-Way, 3- Way, Manifold Mount, Robust solenoid design, Fully Encapsulated coil, Patented IBV ™ diaphragm design making it Contamination Tolerant, PEEK Body, FKM-GF or EPDM Diaphragms and Completely qualified under a wide range of environmental conditions to 100 million cycles. MIV can be configured as a 2 way normally closed, 2 way normally open, a 3 way or a manifold mount 2 way normally closed. The PEEK body and diaphragms are compatible with reagents, saline solutions, lyse, dextrose and bleach to name a few. It is capable of operating up to 35 psig and down to 27 inches of mercury vacuum. The flow capacity is equivalent to a 0.040 equivalent sharp edge orifice or a CsubV of 0.03. Leakage is bubble tight and is available in both a 12- and 24-volt option at continuous duty. Temperature range is 32 to 150 degrees fahrenhieght. Since the MIV and the IDV are considered standard product they have a standard part numbering system. The product has predefined configurations which the customer can use to customize the product specific to their application. We dwell on this slide but if you should like more description please ask at the conclusion of my presentation.
- Another version of the inert solenoid valve is the Inert Diaphragm Valve – IDV formally known as the Inert Dialysis Valve. The name was changed after other applications other than Kidney dialysis was found. It is a Low cost, 2-Way or 3-way, diaphragm isolated solenoid valve made from either EPDM or Viton, an inert valve body made from Ultem which is a polyetherimide or Radel-R which is a polyphenylsulfone. Used in clinical chemistry and kidney dialysis applications handling aggressive medias, blood and blood products, other body fluids, disinfecting agents, reagents, and diluents . High cycle life, ESEOD = 0.115 inches (C v =.24), 24 V coil, fully encapsulated coil, numerous mounting and barb options The two way IDV can be configured with a plastic body and diaphragms which are compatible with reagents, saline solutions, lyse, dextrose and bleach to name a few. It is capable of operating up to 40 psig and down to 27 inches of mercury vacuum. The flow capacity is equivalent to a 0.115 equivalent sharp edge orifice or a C.V. of 0.24. Leakage is bubble tight and is available with a 24 volt coil rated for continuous duty. Temperature range is 0 to 203 degrees fahrenhieght.
- Finally the Servoid Valve is SBC patented proportional valve technology suitable for open loop applications in aerospace and medical life support equipment with an ESEOD of 0.250 inches (C v = 1.125). Available in pressure balanced designs. Low power (5 Watts), low hystersis (typically 3 %), excellent repeatability, high life cycle (over 100’s of million cycles). The Servoid valve is a patented proportional solenoid valve used in both aerospace and commercial applications. The servoid is unique in that it gives almost infinite resolution with no mechanical friction. The servoid’s other unique attribute, which makes it perfect for critical life support applications, is it’s inherent reliability.