Cartridge and block spindles - Gilman USA

Heat transfercore manufacturingmachinery made modularand more accurateSpecialsNo. 2003Idea bulletinDual head rise andfall assembliesApplicationBuilding patented, 12 1000thstolerance aluminum tubeheat transfer cores for theautomotive industry.ChallengeGilman USA was given anopportunity to improve themanufacturer’s 15-year-oldwelding process and helpdesign an entirely new patentedmachine design for decreasedtolerance and modularity. Thismanufacturer of 2.5 millionheat transfer cores a yearwanted standard, adjustableand interchangeablemachine assemblies, andmost importantly, accuracyequivalent to a machine tool.Setting up the new machineshad to be simple. Eachspindle also needed to beindependently adjustable.The heat transfer core manufacturing lineconsists of over 13 stations. Each stationhas two dies that progressively form theapproximately 1/2” wide metal into corecomponents at a rate exceeding 50 fps.SolutionGilman USA designimprovements, developed overa seven year period, allowedthe manufacturer to replace theinduction welding method witha more efficient brazing method,producing a lighter, smallerand less costly core. The newmachines produced cores with.0001 tolerance, compared tothe previous method whichyielded tolerances of .001-.005. The Statistical ProcessControl produced 2-3 CPKon the dimension (5-710ths). The redesignedconfiguration made the coreslighter, 75% of the width and2.5-3% less expensive, saving$.50 per core. The cost ofretooling was quickly offset bythe ease of installation. GilmanUSA was involved in the setupfor six months. The Gilmanbrand components could beinstalled right out of the box sothey required considerablyless manpower. Installedspindles were held to atolerance of 3.5 tenths. TheGilman brand componentsalso used considerably lessspace on the factory floor.54 ©2011 Gilman USA, LLC