Slides/Hangers Manufacturing Solutions
Common Customer Challenges
- Diverse load/deflection requirements and temperature ranges demand multiple support types and precise calibration.
- Material selection (CS/SS/alloy) and coatings (HDG/epoxy/PTFE) must match corrosion categories and site conditions.
- Dimensional and positional tolerances on welded assemblies affect installation fit and load paths.
- Spring support calibration and lock‑out/ship‑out settings are often inconsistent across batches.
- Documentation and traceability (MTRs, calibration sheets, coating DFT) are incomplete or non‑standardized.
- Mixed model, fast turn projects require flexible cells and robust internal logistics.
Solutions And Case Studies
Variable/Constant Spring Supports
- Technical Points: Load/deflection calibration, travel stops, temperature compensation, paint/galvanizing compatibility.
- Process Route: Fabrication → Spring assembly → Calibration → Coating → Functional test → Marking.
- Success Case: 500‑set variable springs for a CCGT plant, calibration tolerance ≤±2%, delivery lead time −25%.
Rod Hangers, Clamps and U‑Bolts
- Technical Points: Thread quality, clamp fit accuracy, galvanizing thread protection, anti‑slip coatings.
- Process Route: Cutting/forming → Machining/threading → Welding → HDG → Torque test.
- Success Case: Petrochem unit revamp, 6,000+ pieces, torque consistency Cpk≥1.33, punch‑list items −60%.
Pipe Shoes and PTFE Slide Plates
- Technical Points: Cold/Hot shoes, wear pads, PTFE–SS bonded slide plates, low‑friction interfaces.
- Process Route: Forming/fabrication → PTFE bonding → Machining finish → Coating → Load/friction test.
- Success Case: LNG pipe rack, coefficient of friction ≤0.08, field alignment time −30%.
Wing Structural Parts Manufacturing Process
Raw Materials And Incoming Materials Inspection
Process step description: Verify aluminum/titanium alloy grade, thickness, surface quality and heat treat condition; sample chemistry and mechanical properties. Equipment: Optical spectrometer, universal testing machine, CMM, ultrasonic thickness gauge, hardness tester, metallographic microscope.
Material Preparation And Cutting
Process step description: Cut sheet metal to required dimensions with minimal waste and proper edge quality for subsequent forming operations. Equipment: CNC cutting machine, laser cutter, waterjet cutter, shearing machine, edge deburring machine.
Forming And Bending
- Process step description: Form clamps/U‑bolts/pipe shoes and brackets to drawing radii and angles.
- Equipment: CNC press brake, roll bender, pipe/rod bender, hydraulic presses, forming dies.
Machining And Threading
- Process step description: Machine holes/slots and cut threads for rods/bolts to tolerance and finish.
- Equipment: CNC lathe, machining center, drilling/tapping machine, thread rolling/cutting machine, gauges.
Welding And Fabrication
- Process step description: Weld shoes, bases and brackets per WPS/PQR with distortion control and fit‑up verification.
- Equipment: MIG/TIG/SMAW welding stations, positioners, welding fixtures, preheat stations, weld gauges.
Heat Treatment/Stress Relief (As Required)
- Process step description: Apply stress relief or heat treatment to meet mechanical properties and reduce distortion.
- Equipment: Heat treatment furnace, stress relief furnace, temperature control system.
PTFE Bonding And Wear Pads
- Process step description: Bond PTFE to SS backing plates and assemble wear pads to pipe shoes.
- Equipment: Surface prep line, bonding press, curing oven, surface roughness tester.
Surface Treatment And Coating
Process step description: Apply anodizing, primer coating or specialized surface treatments for corrosion resistance and paint adhesion. Equipment: Anodizing line, coating booth, curing oven, surface preparation system, thickness gauge.
Calibration And Functional Testing
- Process step description: Calibrate variable/constant springs, set travel stops, conduct load/deflection tests.
- Equipment: Spring calibration rigs, load frames, displacement sensors, data acquisition.
Final Inspection And Documentation
Process step description: Conduct final quality checks, generate inspection reports and prepare documentation for airworthiness certification. Equipment: Visual inspection station, documentation system, barcode printer, quality management software.
Packaging And Shipping
Process step description: Apply protective packaging and shipping preparation to prevent damage during transportation and storage. Equipment: Protective packaging system, shipping fixtures, environmental monitoring, handling equipment.
Data Traceability And Quality Control
- Process step description: Maintain complete traceability of materials, processes and inspections for airworthiness compliance and quality control.
- Equipment: MES, data acquisition system, quality management system, barcode/RFID system, document management.
Slides/Hangers Production Line
Production Line Layout And Configuration
- Overall Layout: Linear/U‑shaped flow by process—cutting → forming → machining → welding → coating → calibration → inspection → packing.
- Workstation Division: Material prep; forming/bending cell; machining/threading cell; welding/fabrication bay; coating/HDG; calibration; inspection/packing.
- Logistic Passage: Main aisle 4–5 m for racks and cranes; buffer zones (4–6 h WIP) before coating/calibration to level takt.
Equipment Configuration And Automation
- Forming/Bending: CNC press brakes (≥200 t), roll benders, rod benders; robotic handling for repeat parts.
- Machining/Threading: Multi‑spindle drill/tap centers, thread rolling lines, CNC lathes; in‑process gauging.
- Welding/Fabrication: Multi‑station MIG/TIG cells, positioners, modular fixtures; weld data logging.
- Coating: Blasting booths, HDG line or paint booths with curing ovens; automatic DFT measurement logging.
- Calibration: Dedicated spring calibration rigs with digital load/deflection capture, automatic labeling of set‑points.
- Inspection/Packing: Gauge stations, marking/labeling cells, VCI packing line with crate assembly.
Production Flow And Material Handling
- Material Flow: Raw materials → Rough machining → Heat treatment → Precision machining → Assembly → Inspection → Packaging
- Handling: Overhead cranes (5–10 t), forklifts, pallet jacks; AGVs optional for cell‑to‑cell transfers.
- Storage: FIFO racking by project and support type; kitting carts for site erection sequences
- Digital control: MES routing, barcode traveler, auto program selection per fixture ID.
