Tour of Racks Unlimited

• Tour Start
• Sales, Management & Front Offices
• Manufacturing Departments
• Assembly and Finishing

Racks Unlimited Manufacturing Departments

This section of our Tour will include our - 

Quality Control

Every operation is continuously monitored. Micrometers, Vernier Calipers and Coordinate measuring machines are used constantly to insure accuracy within permitted tolerances. 

The extensive quality controls (Mil-I-45208A) and SPC assure consistency and the high quality that Racks Unlimited guarantees it customers.

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Shearing Department

Our Shearing Department consists of several shears enabling Racks Unlimited to cut all the appropriate part sizes needed to meet all our standard, custom and specialty Electronic Rack Enclosure orders

CNC Turret Department

Amada is one of the most prestigious names in quality fabricating equipment.

Our sophisticated Amada CNC Turret presses are state of the art machines... completely automated and fully computerized with "DNC" direct numerical control from engineering to our CNC turret presses, eliminating the need for paper tapes.

Prototypes and production runs are produced quickly and inexpensively at speeds of 220 to 900 hits per minute on one inch centers. Special added features are our four 4.50" auto index stations that are capable of punching 360 degree and up to 900 hits per minute bi-directional.

Another added feature is our newest acquisition the Vipros 358 King, which is a fully automatic hydraulic turret press which is unparalleled in controlling marks. It's ram control is excellent in allowing forming capability, which enables Racks Unlimited to produce a completed part without secondary operations.

This allows your designer to create any shape or angle desired at a very low cost. Our turret presses hold up to 86 different tools from .032 to 4.500 diameter and are capable of punching up to .250 thick material and blank sizes of up to 50" x 144". 

Stamping Department

Racks Unlimited offers a variety of processes to insure low cost of manufacturing with volume production.

Our Stamping Department involves stamping presses from 15 tons to 100 tons. All tools are manufactured in-house and are maintained by our on site tool & die makers.

Laser Cutting Department

Racks Unlimited was one of the first in the Electronic Rack Industry to use Laser Cutting technology. That makes Racks Unlimited one of the most experienced Laser cutting Electronic Rack Enclosure Manufacturers!

Mazak is one of the leaders in laser cutting technology and that is why  Racks Unlimited chose to use their turbo 48 1500 watts and with supper pulse of 2000 watts.

This laser can cut up to 1/2 inch thick steel or stainless steel. This incredible laser can process material in sheet sizes of up to 50" x 100" with cutting speeds of 200 inches per minute on 1/16 thick material, eliminating the need for any special tools or setups.

Normally, there are many different tools used in a turret, which is not needed in laser processing.

Today's laser cutting technologies allows us to cut almost any type of material from very hard aircraft alloy to a variety of plastics and non metal materials without leaving any step marks or burrs.

Graining & Deburring Departments

Racks Unlimited Graining Department consists of several different size machines, ranging from 8 1/2 to 37 inches of graining capacity.

All of our blanks that are punched off our CNC turret presses and our stamping presses are all processed through our array of graining machines. All parts are grained to eliminate all scratches and burrs that are protruding to insure the highest quality presentation of cosmetic parts.

All of our custom sheet metal parts are guaranteed to be burr free.
Our state-of-the-art grain deburring machine allows us to deburr all edges and holes.

This new technology was designed for the aircraft industry which consists of a conveyer and a disc made of emery cloth approximately 40 inches diameter that spins at a very high speed while the parts are being fed through by means of a conveyer belt.

This eliminates the need of any hand deburring, which in turn reduces part costs of all our Electronic Rack Enclosure parts and accessories.

Forming Department

Racks Unlimited has a full array of forming machines.

We are always looking to be on the leading edge of technology in today's highly competitive market.

That's why Racks Unlimited chose to use Amada fabrication equipment.

From 50 tons to 100 tons and from 4 feet to 10 feet in length, all of our machines are fully computerized and fully hydraulic to insure total accuracy while forming. Each machine is equipped with a six axis gauging system to insure total part accuracy.
  

Spotwelding Department

Racks Unlimited Spotwelding Department consists of Sciaky spotwelders.

Sciaky is one of the oldest and most well recognized names in spotwelding equipment. By using the best spot welder on the market, we get maximum spotweld penetration.

Sciaky welders are one of the best welders of aluminum and steel on the market today. With our Sciaky welder Racks Unlimited can weld 1/8 to 1/8 thick, to mil specifications.

Welding Department

Racks Unlimited's Welding Department consists of both manual and robotic welding machines.

All of our welders are highly trained and skilled. With their many years of experience we are able to weld any material. Our welder normally welds with mig or tig.

Our Fanuc robotic welders are equipped with two pallets that rotate 360 degrees each, and can hold parts sizes of up to 36 x 36 x 96 on any of our four loading stations, which dramatically increases our through put.

One of the Fanuc robotic welders great features is its ability to weld at speeds of up to 100 inches per minute automatically without any part handling. While one of our four machines is welding we are able to load and unload parts from our other stations which insures constant welding. Just another efficiency that Racks Unlimited offers it's customers!

Grinding Department

Grinding is one of the processes that today is still a manual process, and very time consuming.

Racks Unlimited uses skilled personnel to insure that all welds are ground and polished to insure an exceptionally good looking finished product.

Drilling and Taping Department

At Racks Unlimited a full array of drilling machines are available from single drill presses, to multi-head drilling machines, to our Burgmaster turret drill press with six head rotary index.

The Burgmaster turret drill press can have multiple heads with either drills or taps installed in one setup. This allows you to handle parts just once while performing many different taps before replacing your part. An advance tapping machine table has been installed to allow a large area of tapping of a variety of different taps from 2-56 to 1/2 taps, all in one setup.

Hardware Department

Racks Unlimited has equipped its Hardware Department with the most advanced hardware insertion equipment on the market today.

A full range of Heager press from 18-inch throat to 24 inch is available which allows us to insert any hardware on the market today

One added feature is our automatic hardware insertion bowls that allows us to fill it with a variety of hardware for high volume hardware insertion

Racks Unlimited is able to produce your products quickly and efficiently which cuts down on your cost!

Tool & Die Department

Racks Unlimited's Tool & Die Department is staffed with highly skilled tool and die makers. We are capable of making simple tools to the very complicated progressive stamping tools, needed in this highly competitive market.

Today a fabricator needs to be able to have total control over all of its process's to compete. From simple drill fixtures to complicated tools, all tools must be made in a very short lead time. Racks Unlimited provides all of these services daily.

Sawing Department

Amada Cutting Technologies is the world's leading producer of metal cutting machines. The reason is quite simple, an uncompromising commitment to quality. Through a continuing program of research and development in metallurgy and manufacturing processes, Amada has developed many of the most significant advances in blade and machine technology.

	Faster Cycle Times with Quick Approach Bar, which quickly lowers blade into cutting position then slows to the appropriate speed for the cut.
	Assured Accuracy with the heavy-duty Guiding Mechanism, along with our special Index Vise, which pulls away from the stock on both sides to avoid inadvertent material movement during shuttling; guaranteed cut-off repeatability of +/- .002".

The Amada HA-250 is one of the most precise saw cutting machines today, giving unbelievable cutting accuracy of plus or minus .001 thousand of an inch. With a completely square saw cutting processes, completely computerized with a rapid feed option that allows total unmanned process to insure a low cost of fabrication for your product.

Racks Unlimited is proud to use Amada products in it's manufacturing process. We will be adding pictures from our own sawing department into this section shortly.

Milling Department

With a full line of milling machines from Manuel Bridgeports to Mazak's cnc machining center equipped with automatic pallet changers.

Our cnc-machining centers are capable of unsurpassed quality and accuracy to insure the most accurate parts that can be produced.

All of our cnc milling machines are fully loaded with a complete turret of tools and fully computerized to our engineering department.

This direct network link with our engineering department via direct numerical control "DNC" is what allows Racks Unlimited to guarantee the utmost accuracy in transferring information.