Summary
Engineering Resources Plus (ERP) was contracted by TronAir to design and build a 60 Ton Jack Tester for testing jacks designed for lifting aircraft for towing and maintenance service. ERP contracted Toolcraft for the machined parts of the assembly, Motion Industries for the mechanical drives, and Parker for the hydraulics. ERP rented a build space on-site with Toolcraft, fully assembled the unit to test functionality before disassembling and transporting to the TronAir facility and re-assembling for delivery.
Overall Specifications
The project for Tronair involved the manufacturing of a critical 60 Ton Jack Tester component used in aviation ground support equipment. The specifications included:
- Materials: 1018 Low Carbon Steel, 8620 Alloy Steel, A36 Mild Steel, 4140 Pre Hard, 4340 Medium Carbon Steel, 6061 Aluminum
- Machine Dimensions: Approximately 14 feet tall at rest
- Quantity: 1 complete assembly
- Tolerances: Various; maintained as close as .0005″ on certain features
- Finish: Painted after assembly and test at Toolcraft facility
- Maximum Load: 180,000 pounds
- Minimum Load: 6,000 pounds
- Largest Jack Height: 18 feet
- Smallest Jack Height: 6 inches
- Largest Jack Tripod Diameter: 8 feet
- Width Between Columns: 6.3 feet
Uses and Applications
The 60 Ton Jack Tester component manufactured by Toolcraft is a vital part of Tronair’s aviation ground support equipment, which is used to service, maintain, and repair aircraft. The applications include:
- Aircraft Maintenance: Facilitating the safe and efficient maintenance of various aircraft.
- Ground Handling: Supporting ground operations to ensure timely and effective handling of aircraft.
- Repair Operations: Providing essential support for repair activities, minimizing aircraft downtime.
Capacity
Toolcraft’s advanced manufacturing facility is equipped with state-of-the-art machinery and technology, allowing for:
- High Volume Production: Capable of handling large-scale production runs with consistent quality.
- Precision Machining: Utilization of CNC machines for precise and repeatable manufacturing.
- Customization: Flexibility to accommodate specific customizations required by Tronair.
Quality Control
Toolcraft adheres to strict quality control measures to ensure the highest standards of manufacturing excellence:
- Inspection: Thorough inspection of materials and components at every stage of production.
- Tolerance Verification: Ensuring all dimensions and tolerances are within specified limits using advanced measuring instruments.
- Functionality Testing: Comprehensive testing to verify the functionality and performance of the component.
- Final Review: A detailed final inspection before delivery to ensure the component meets Tronair’s exacting standards.
Quality Control
Toolcraft’s comprehensive quality control procedures ensured the Brass Die scraper met stringent performance and reliability standards:
- Dimensional Inspection: Coordinate Measuring Machines (CMM) were used to verify all critical dimensions and tolerances.
- Material Testing: Metallurgical tests were conducted to confirm the material’s properties and compliance with specifications.
- Non-Destructive Testing (NDT): Techniques such as ultrasonic testing and magnetic particle inspection were employed to detect any internal or surface defects.
- Functional Testing: The assembled Brass Die scraper underwent rigorous functional tests to ensure proper operation and integration with Michelin’s manufacturing process.
- Final Inspection: A thorough final inspection was performed to validate the overall quality and readiness of the Brass Die Scraper before delivery to Michelin.
Manufacturing Process
The manufacturing process for the Tronair Jack Tester component involved several key steps:
Design Review
Collaboration between Toolcraft’s engineers and Tronair to finalize the design and specifications.
Material Selection
Sourcing 1018 Low Carbon Steel, 8620 Alloy Steel, A36 Mild Steel, 4140 Pre Hard, 4340 Medium Carbon Steel, and 6061 Aluminum to meet the durability and performance requirements.
CNC Machining
Using advanced CNC machines to achieve precise dimensions and tolerances.
Surface Treatment
Applying a corrosion-resistant finish to enhance the component’s longevity.
Assembly and Testing
Assembling the component and performing rigorous testing to ensure it meets all functional requirements.
Project Gallery
Conclusion
The collaboration between Toolcraft and Tronair resulted in the successful manufacturing of a high-precision 60 Ton Jack Tester component that meets the rigorous demands of the aviation industry. Toolcraft’s commitment to quality, precision, and customer satisfaction ensured the project’s success, providing Tronair with a reliable and durable component for their ground support equipment. This partnership exemplifies Toolcraft’s ability to deliver exceptional solutions tailored to the specific needs of their clients in the aviation sector.