Challenge
Premetec was tasked with the intricate challenge of manufacturing a high-precision hydraulic pipe/block subassembly tailored for industries. This project demanded not only precision manufacturing but also the assembly of multiple components with stringent positional tolerances. The complexity further extended to TIG weldings for frame structures and the assembly of 40 connector parts, all with a positional tolerance of +/- 0.5mm across a staggering length of 6,000 meters. Furthermore, the subassembly had to undergo hydraulic oil flushing and final testing, with zero allowances for any leakages.
Insight
Single-setup manufacturing: The project began with single-setup manufacturing using a state-of-the-art 5-axis CNC machine. Premetec’s skilled machinists handled the process from raw material to the final part, ensuring tolerances and seamless integration of components.
TIG welding expertise: Precise TIG welding techniques were employed to create the frame structure and connect the 40 individual parts. Each weld had to meet the demanding positional tolerance of +/- 0.5mm, ensuring structural integrity.
Hydraulic pipe assembly: The assembly process included the meticulous arrangement of hydraulic pipes, requiring exacting precision to guarantee seamless functionality.
Hydraulic oil flushing: After assembly, the subassembly underwent hydraulic oil flushing, a critical step to ensure the cleanliness and optimal performance of the hydraulic system.
Hydraulic pressure testing: Final testing was conducted under hydraulic pressure, with zero tolerance for any leaks. This step validated the subassembly’s reliability and functionality in a real-world application.
Results
Premetec’s commitment to precision and excellence resulted in outstanding outcomes:
High-precision subassembly: The hydraulic pipe/block subassembly was manufactured with exceptional precision, meeting all specifications and positional tolerances of +/- 0.5mm over an impressive length of 6,000 meters.
Structural integrity: The TIG weldings for the frame structure and connector parts were executed flawlessly, ensuring the subassembly’s structural integrity.
Seamless hydraulic functionality: The assembly of hydraulic pipes, coupled with meticulous hydraulic oil flushing and testing, guaranteed the subassembly’s seamless hydraulic functionality.
Client satisfaction: Our client received a subassembly that not only met their rigorous requirements but also exceeded their expectations. The success of this project reinforced the partnership between Premetec and the client, highlighting our commitment to excellence in industrial manufacturing.
In conclusion, this case study underscores Premetec’s expertise in engineering and assembly, particularly in demanding industry sectors. Our ability to manufacture and assemble complex components with precision and reliability also positions us as a trusted partner in the industry.