Notable Achievments – GD AUTOMATION

Notable Achievements & Projects

GD Automation is recognized as an industry leader in delivering innovative, turnkey automation systems that drive efficiency, productivity, and quality across manufacturing sectors worldwide. We have consistently delivered world‑class custom automation solutions ranging from small precision machines to fully integrated, multi‑million‑dollar assembly lines. Some of our notable achievements & Projects are....

1.300-Foot Superconductor Wire Drawbench

Designed and implemented a pioneering 300-foot drawbench system for superconductor wire extrusion. Integrated a complex harmony of electrical and hydraulic servo mechanisms. This first-of-its-kind system contributed directly to the manufacturing of superconductive wire now used in many MRI machines.

Siemens motion controller, PLC, HMIs & many drives

2.High-Speed Indexing Equipment for Automotive Airbag Production

Designed a rapid-indexing machine that processes dual-ply material for airbag systems. Achieved two-second indexing of a vacuum bed with over 6 foot lengths of material, sealed the plies together in-line, eliminating the need for a separate mending stage.

Delta Tau motion controller & Parker drives

3.Legacy System Retrofit for Sticky Mat Production

Modernized a legacy, web-based production system imported from Asia for a major industry leader. Translated foreign-language interfaces, restructured the PLC source code, and integrated updated controls for full production deployment.

Siemens PLC, remote PLC, HMIs, & ABB drives

4.High-Throughput Threaded Insert Production System

Created advanced equipment for producing Heli-Coil-style threaded inserts at 1.5 to 2.5 times the rate of the client’s previous machinery lineup, dramatically increasing throughput and reliability.

Delta Tau motion controller & Kollmorgen drives & A-B VFD

5.Precision Laser Grid Welding System for Nuclear Industry

Developed a multi-stage laser welding system for complex grid assemblies used in nuclear fuel. The system reduced welding cycle times from 45 minutes to under 20, significantly enhancing production efficiency. Developed a transformation‑matrix algorithm that re‑maps laser‑firing coordinates inside the controller, precisely rotating them to align with the machine’s physical grid for fault‑free targeting.

Delta Tau motion controller & Proface HMI & Elmo drives

6.High-Capacity Rolling Mill for Mining Applications

Engineered a massive rolling mill used to produce cathode sheets for the strip mining industry in the mountains of Arizona. The material was initially a 4-inch thick lead slab, which was gradually reduced through successive rolling stages to produce uniform 1/4-inch sheets. The innovative progressive rolling process reduced manufacturing cycle times by 75%.

A-B motion controller, PLC, HMIs & ABB VFDs

7.High-Speed Traversing Take-Up System for PV Wire Production

Developed a high-speed take-up system for a 3-head rolling mill used in photovoltaic (PV) wire production. Handled 2000 lb copper spools at speeds exceeding 2,200 FPM—more than double the previous 900 FPM benchmark. This wire is used in solar panels manufactured by Solar City and other leading companies.

Delta Tau motion controller & Proface HMI & Parker drives

8.Hybrid Control Architecture for Rolling Mill Integration

Successfully integrated a Delta Tau motion controller, Proface Modbus HMI, and Siemens ProfiBus drives into a unified control system for a streamlined rolling mill. This complex integration overcame significant technical challenges and paved the way for modular, scalable automation solutions.

Delta Tau motion controllers & Proface HMI & Siemens drives & Parker drives

9.Ultra-Precision Lithium Rolling Mill for Energy Research

Engineered a precision control system for a laboratory-scale lithium rolling mill serving the power industry in Canada. Achieved exceptional sheet uniformity at thicknesses down to 7 microns—critical for next-generation battery research and development.

Siemens motion controller, PLC, HMI & drives