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Home
About
Capabilities
Products & Services
Industries
Resources
Contact
Transparency in coverage

PRODUCTS & SERVICES

Check out our capabilities!

Hose form tooling
Hose Form Assembly and Check Fixtures
Trim Fixtures
Contract Machining
ABBEY ETNA ROTARY SWAGERS
Production machining
Custom Machine Builds
Elevator Components

HOSE FORM TOOLING

Jerl Machine has produced Hose Form Mandrels for over 25 years. Our internal designed CNC Benders are state of the art. Using custom-tailored software we can quote and design your projects with exceptional speed producing prints within a day and prototype parts in 2 – 3 days from design approval. Production capabilities allow order sizes of 20 to 500 mandrels to be processed quickly and in a cost effective manner to meet your high volume requirements.

Hose Form Mandrels

Steel, Stainless Steel, Aluminum
Up to 2 1/4" diameter bending capability
Accessories available to maintain control diameters and overall length
Designed to maximize autoclave space

CNC Solid Stock Bender

CNC bending capability maximizes efficiency and repeatability
Aluminum ~ Stainless Steel ~ Cold Roll Steel ~ Cast ~ Machined
Bend up to 2 1/4″ diameter solid aluminum stock
Bend up to 1 1/2″ diameter solid cold rolled steel
Gemlux coating available for ease of operation
Rapid Prototype (2-3 day turnaround) and production capability

Check Fixtures

100% Certified through CNC CMM
Certified inspection reports provided
Used as master to inspect 100% of mandrels

Design Capability

SolidWorks 2014 ~ AutoCAD 2009 ~ MasterCAM
Collaborate with your design team to maximize oven efficiency
Solid Modeling Capability
Custom-tailored software allows for rapid design times

HOSE FORM ASSEMBLY AND CHECK FIXTURES

Design and build complex assembly and check fixtures with multiple components. We can meet all your inspection and assembly requirements by integrating multiple features into one gauge or fixture. We offer GDT designs, incorporate hose clamp orientation, hose length, Go/No Go, and accommodate clearances for connectors and fittings. We will also design fixtures to inspect integrated steel and rubber assemblies.

Hose Form Assembly

100% Dimensional CMM Inspection
Certified Assembly and Check Fixtures
Complex Feature Characteristics

Design Capability

Design using SolidWorks 2014 & AutoCAD 2009
MasterCAM X for CAD & CAM software
Solid modeling capability
Translators available to handle most file formats

Check Fixtures

Mandrels certified to a 100% CMM inspected Check Fixture
Solid Modeled
Certified results with PDF reports available at customer's request

Assembly Fixture and Inspection Gauge

Incorporate inspection and assembly into one fixture or gage
Go/No Go for overall lengths
Hose clamp rotation locators available
Connector positions
Assembly of small components

TRIM FIXTURES

Jerl Machine offers three styles of cutter bodies that can be incorporated into trimming rubber hose to length. Both patented and patent-pending design cutters maximize tool life while providing efficiency (minimal end trim). We stock all spare parts and can meet the most challenging of applications.

Trim Fixturing

Minimize end trim
Patent-pending cutter blade design
Stock spare parts

Design Concept

Design using SolidWorks 2014 & AutoCAD 2009
MasterCAM CAD / CAM software
Solid Modeling capabilities
Translators available to handle most formats

Trim Fixtures

Minimize end trims
Diameters from 1/4″ to 2 3/8″ diameter
Proprietary cutter blade design minimizes end trim & promotes clean, straight cuts
Designs to handle multiple parts per cycle

Cutter Bodies & Spare Parts

Stock entire replacement units
Stock cutter bodies and blades
Ship within 1 – 2 business days

CONTRACT MACHINING

Since 1975, Jerl Machine has experience in providing full service metalworking and precision machining for a wide variety of industrial and manufacturing customers. Our continued investment in people, technology and systems allows us to hold tight tolerances of .0005 on several features per print including GDT, flatness, parallel and squareness.

Full Service Machine Shop

Specialize in tight tolerance machining
Raw Stock ~ weldments ~ castings ~ forgings
Steel ~ aluminum ~ stainless steel ~ steel alloys ~ exotic alloys
Stress relieve ~ heat treat ~ anodize ~ black oxide

CNC Milling and Turning

22 CNC machines
Large part capability up to 22,000 lbs.
VTL's and horizontal lathes with live tooling capability
Vertical and horizontal milling machines
CNC boring mills with full 4th axis

Manual Milling and Turning

Lathes up to 13 foot travel
Bridgeport mills
Boring mills with rotary table
Planer mill

Miscellaneous

Surface, Blanchard, OD & ID grinding
Key seating
Paint Honing

ABBEY ETNA ROTARY SWAGERS

The Abbey Etna Machine Company, established in 1901, built rotary Swagers for decades earning an industry wide reputation for quality, dependability and endurance. In 2002, Jerl Machine, Inc. acquired the Abbey Etna line of rotary Swagers and continues the tradition of excellence and durability.

Electric escalator in yellow bands and metal line steel

Elevator Installation, Lift Technician Installing a Modern Elevator

Features of the Abbey Etna Rotary Swager

Heavy duty
Highly standardized
Capable of long tapers in a single pass
Reduces, sizes and forms round tubes and solids
Hot swaging
Semi-automatic feed systems
O.D. and I.D. holding services
Roll type feeds
Die closing attachments, used for center reductions

The 150 Swager is also available with a 3.000″ wide die slot. The max. tube capacity is light gauge 2.000″. The motor spec is 10 hp.
The 190 series max. tube capacity of 2.250″ applies to light gauge tube only.
The 190 through 600 series Swagers are available as two (2) or four (4) die units.
The 900 series Swager which has a 8.000″ max. tube capacity and a 4.000″ max. solid capacity with an 8″ to 16″ die length.
The specifications shown above are typical of two (2) die Swagers.

Rebuild Programs

Spare Parts

Rotary Swager Specifications

MODEL #	30	70	100	150	190	200	300	400	600
Max. Tube Capacity	.375″	.750″	1.000″	1.500″	2.250″	2.000″	3.000″	4.000″	6.000″
Max. Solid Capacity	.187″	.375″	.500″	.750″	.875″	1.000″	1.500″	2.000″	3.000″
Width of Die	1.000″	1.375″	1.875″	2.500″	3.000″	3.250″	4.500″	5.750″	8.500″
Thickness of Die	.750″	1.125″	1.125″	1.625″	1.875″	2.250″	3.250″	3.750″	6.000″
Number of Rolls	10	10	10	16	18	18	20	20	20
Diameter Cage Roll	1.125″	1.437″	1.562″	1.963″	2.125″	2.375″	2.718″	3.303″	4.800″
Center Height	36″	36″	36″	36″	38″	40″	42″	42″	44″
Overall Height	42″	47^1/8″	52″	54″	56″	86^3/8″	95^3/4″	97^1/2″	116″
Flywheel Diameter	10^3/8″	20″	28^1/2″	31^5/8″	31^5/8″	41^1/8″	47^3/4″	53^3/4″	63^1/4″
Flywheel Face	2^3/16″	4″	4^1/2″	5″	5″	6^1/2″	9″	10^3/4″	17″
Dia. Hole Through Spindle	^5/8″	1^1/16″	1^5/16″	1^3/4″	2^9/32″	2^9/16″	3^3/16″	4^1/4″	6^1/2″
Wt. Machine Skidded (LBS)	700	1430	2530	4500	6500	11250	19000	23400	44000
Motor RPM	1800	1750	1750	1150	1200	1150	860	690	575
Spindle RPM	600	400	375	200	200	175	165	145	120
Motor HP	1	2	3	7.5	15	15	25	40	75
Hammer Blows Per Minute	6000	4000	3750	3200	3780	3150	3300	2900	2400
Die Lengths Available	1″-2″	2″-6″	3″-6″	4″-18″	6″-18″	6″-16″	6″-16″	6″-24″	8″-18″

PRODUCTION MACHINING

Since 1975, Jerl Machine has experience in providing full service metal working and precision machining for a wide variety of industrial and manufacturing customers. With a focus on lean manufacturing, Jerl Machine employs modular fixture design concepts which results in the rapid and efficient production of parts in an economical manner. Major machining products include spindles, shafts, gears, pump housings, natural gas cylinders, connecting rods, gear boxes and weldments.

Inspection Process

ISO 9001 Certified, we believe continuous improvement and a common sense approach to process control are the key ingredients to superior quality. At Jerl Machine, we value quality from order entry through shipment.

Jerl Machine believes quality is built in the process. Our toolmakers pride themselves in making sure each dimension they have machined conforms to print tolerances, and are required to sign off on their operation prior to advancing it to the next work station.

Significant investments in gauging, high end tooling, fixtures, and equipment allow us to provide repeatability and reproducibility at a cost effective price.

Production Machining

Low and High Volume
Part Family – High Product Mix low Volume
Precision ~ Tight Tolerances
100% In-Process Inspection
Part Kitting

Packaging
Modular Fixture Design reduces lead time and improves flexibility
Order Tracking and Scheduling
Program Management

Production Capabilities

CNC Capabilities
Small Batch Repeat & Continuous Flow
Part Family – Process Focused

Design & Modular Fixture Concept

MasterCAM Solid Modeling
Employ Modular Concepts to incorporate accuracy and flexibility
Lean Concepts

In Process Inspection Forms

Print-critical features are stamped “F” for feature to be inspected
Standard In Process Inspection Form used
State of the art technology
Inspection per automotive specifications

CUSTOM MACHINE BUILDS

Jerl Machine has extensive experience in the mechanical assembly of complex custom machinery. Within our 80,000 sq. ft. facility we offer a 15,000 sq. ft. high bay assembly area with up to 25 ton crane lifting capacity. Jerl has assembled up to eight special machines at one time. We manage projects from prototype through final assembly.

Custom Machine Builds

Build to print ~ manage entire assembly
Fabricate ~ machine ~ paint ~ assemble
Mechanical ~ electrical ~ pneumatic ~ hydraulic
Large 15,000 sq. ft. assembly area – 30 foot high, 24 foot under crane
Cranes up to 25 ton capacity

Major Component Sub-Assemblies

Gear Boxes ~ spindles ~ bearings ~ seals
Rebuild ~ reverse engineering capabilities
Production assembly
Rebuilds ~ disassemble ~ clean ~ inspect ~ quote

Elevator Components

Jerl Machine has over 25 years of experience in providing a wide variety of major assemblies, repairs and rebuilds, and individual machined components for the elevator industry. We offer complete program management capabilities that include stocking programs, part kitting and barcoding. Jerl is equipped to handle contract machining needs, breakdowns, rebuilds and spare parts needs.

Motor & Roller Guide Adapters

Motor Adapters

Plate kits with hardware
Couplings / Inserts
Part kits with barcoding

Roller Guide Plate Adapters

Stock over 200 part numbers
Industry standard and custom plates available
Short lead times (7 – 10 days)
Stocking programs available

Couplings & Hardware
Rope Gripper, Bedplate, Overhead Weldments & Complete Assemblies

Governor Rebuilds & Encoder Kits

Jerl Machine has the capability to completely rebuild to OEM specifications including testing and warrantied as new. Our process is to disassemble, inspect, recommend required spare parts, reassemble, test and paint.

B22 – B5 – V16 Rebuild Program

Complete to OEM Specification
Optional – with Encoder Kits
All rebuilds set and tested per customer specification
Short lead times - typically within one week of order

Governor Components

Sheaves & Jaws
Shafts and bearings

Sheaves & Sprockets

Jerl Machine has extensive experience in the manufacture of all types of sheaves, sprockets, shafts, bearings, and related components to meet your needs.

Geared & Gearless Sheave Assemblies

Castings ~ weldments ~ burnouts ~ foam patterns
Sheave grooving
Complete new and rebuild sheaves (shafts and bearings included)

Escalator Head Shaft Assemblies

Escalator sprockets
Bull gears available
Split for ease of assembly

Emergency Response

Jerl Machine handles a variety of breakdown repairs related to the elevator industry. Whether it is an escalator, elevator component, or major sub-assembly, we can respond with technical assistance rapidly and help solve your problem. We can sleeve, weld, chrome and grind, as well as make components new from weldments or raw materials.