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Turnkey Projects

A MAJOR TURNKEY PROJECT TO MANUFACTURE VALVE BODIES AND PLUGS

THE TURNKEY TASKS WERE

TO MODIFY THE DESIGN A BASIC WICKMAN BENNETT AEROTURN 180-200 PRECISION VERTICAL TURNING CENTRE TO ENABLE THE ANGULAR GRINDING OF VALVE BODIES AND PLUGS IN A HIGHLY FLEXIBLE, HIGH PRODUCTION PROCESS

TO PRODUCE THE MANUFACTURING DRAWINGS FOR THE MACHINE, TO SOURCE THE COMPONENTS AND TO BUILD AND COMMISSION THE MACHINE

TO LIAISE WITH CUSTOMER’S ENGINEERS AND DEFINE THE REQUIRED PRODUCTION PROCESSES

TO DESIGN AND MANUFACTURE A FLEXIBLE AND FAST CHANGING COMPONENT FIXTURE SYSTEM WITHOUT INCURRING THE COST OF A FULL OFF MACHINE SET UP SYSTEM

5. TO WRITE THE MANUFACTURING CNC PROGRAMS
6. TO INSTALL AND COMMISSION THE MACHINE
7. TO DEVELOP THE PRODUCTION PROCESS IN TEST RUNS
8. TO TRAIN PERSONNEL IN PROGRAMMING AND OPERATING [MAINTENANCE TRAINING TAKES PLACE DURING PLANNED MAINTENANCE PROGRAMME VISITS]

THE TOTAL PROCESS WAS COMPLETED IN 8 MONTHS FROM ORDER

A BASIC AEROTURN

THE AEROTURN WITH ANGULAR GRINDING FOR THIS PROJECT

CONCEPTS DEVELOPED THROUGH TO FINAL DESIGN

Macintosh HD:Users:Iain:Desktop:8027 Schuf:09DA00 FULL MACHINE ASSY-1.PDF Macintosh HD:Users:Iain:Desktop:8027 Schuf:09DA01 BASIC MACHINE ASSY 21-5-09.PDF

Macintosh HD:Users:Iain:Desktop:8027 Schuf:09DA00 FULL MACHINE ASSY 12-1-09.PDF  Macintosh HD:Users:Iain:Desktop:8027 Schuf:09DA00 FULL MACHINE ASSY.PDF

Macintosh HD:Users:Iain:Desktop:8027 Schuf:09DA00 FULL MACHINE ASSY.JPG

SMALL VALVE BODY AND PLUG (typical component from a wide size range)

FIXTURE SYSTEM TO ENABLE PRECISION TURNING, DRILLING, THREADING AND PRECISION ANGULAR GRINDING FOR TOP QUALITY PRESSURE SEALING

Macintosh HD:Users:Iain:Desktop:09DW08 12 INCH OP1 SET UP.jpg Macintosh HD:Users:Iain:Desktop:09DW09 12 INCH OP2 SET UP.jpg

Macintosh HD:Users:Iain:Desktop:09DW0B 12INCH OP3 SET UP.jpg Macintosh HD:Users:Iain:Desktop:09DW0C 12 INCH OP4 SET UP.jpg

Macintosh HD:Users:Iain:Desktop:09DW0F-B 12INCH PLUG OP 1 SET UP.jpg Macintosh HD:Users:Iain:Desktop:09DW0G 12INCH PLUG OP 2 SET UP.jpg

                  Macintosh HD:Users:Iain:Desktop:WBlogo.jpg

LARGE SERIES VALVE BODY AND PLUG

FIXTURE SYSTEM TO ENABLE PRECISION TURNING, DRILLING, THREADING AND PRECISION ANGULAR GRINDING FOR TOP QUALITY PRESSURE SEALING

Macintosh HD:Users:Iain:Desktop:09DW05 30INCH OP1 SET UP.jpg Macintosh HD:Users:Iain:Desktop:09DW07 30 INCH OP2 SET UP.jpg

Macintosh HD:Users:Iain:Desktop:09DW0A 30INCH OP3 SET UP.jpg Macintosh HD:Users:Iain:Desktop:09DW0D 30 INCH OP4 SET UP.jpg

Macintosh HD:Users:Iain:Desktop:09DW0E 30INCH PLUG OP 1 SET UP.jpg Macintosh HD:Users:Iain:Desktop:09DW0H 30INCH PLUG OP 2 SET UP.jpg

:Schuf pics:Fixtures 2.jpg :Schuf pics:Fixtures 4.jpg

INSTALLATION – WAS IN A VERY TIGHT SPACE

:+:Unload at SchuF:DSC00387.JPG :+:Unload at SchuF:DSC00382.JPG

:+:Unload at SchuF:DSC00364.JPG  :+:Unload at SchuF:DSC00414.JPG

:+:Unload at SchuF:P2150019.JPG

THE ABOVE INSTALLATION WAS COMPLETED TO THIS STAGE IN TWO DAYS, MADE EASIER BY THE SUPERB MOBILE CRANE AND DRIVER

:+:DSC00794.JPG

:Aeroturn :Aeroturn 180-200 pics:operator inspection.jpg

THE TOTAL ASSEMBLY OF THE COMPLEX MACHINE AND GUARDING, START UP, ALIGNMENT TESTING AND FULL FUNCTIONS TESTING WAS COMPLETED IN 11 DAYS FOLLOWED BY TRAINING PROGRAMMING AND PROCESS DEVELOPMENT

:Schuf pics:1 coolant 1.jpg

:Schuf pics:7 Grinding ram.jpg :Schuf pics:9 Live ram.jpg

:Aeroturn :Aeroturn 180-200em pics:Bore grinding.jpg

 
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Wickman Bennett