Technology

Everything you need for bespoke control block systems

Construction

One step ahead with individual hydraulic solutions

Designers are waiting for you at POWER-HYDRAULIK to assist on your project as problem solvers. To your specifications, we will then design your individual control blocks on modern CAD systems. During that process, our experts will also point out alternatives and potential ways to improve things to you. You can always depend upon receiving the perfect control block to meet your requirements.

Process

Frictionless processes. Fully digital.

The required NC data records are generated directly from the CAD design data. Additional CAM functions enable the requisite tools to be set up precisely. Our control blocks often feature very many transverse bores. Tool breakages and costly downtime can be avoided by selecting the optimum machining process at the programming stage, and by running pre-production program simulations.

  • CAD/CAM system: Top Solid V6
  • Data import: Inventor IPT, STEP, DXF
  • Connection to TDM tool management system

Production

Only ever the very finest. For optimum quality.

The production of high-quality and economical control blocks and prototypes calls for state-of-the-art automated and flexible production technology. Our CNC machining centers are unmanned, and are loaded with machining orders in a fully automatic process through anencapsulated material and pallet store.

An overview of the full POWER of our manufacturing facility:

  • CNC machining centers for one-off, prototype and volume production, ideal for a wide range of components and materials, and also for heavy-duty machining
  • Large tool magazines for short chip-to-chip times and retooling parallel to primary time
  • 7 x Heller 4-axis machining centers, fixture clamping weight of up to 1000 kg, edge length up to 1000 mm, tool magazine with 425 tools, max. drilling depth of 800 mm
  • 1 x Hermle 3-axis machining center for prototype production
  • Full Service maintenance contracts for productivity and for less unscheduled downtime

Deep-hole drilling

Deep-hole drilling - our ultimate discipline

At POWER-HYDRAULIK, reliability in the deep-hole drilling process is an everyday reality. With our HELLER machining centers, we can performautomated deep-hole drilling operations in aluminum, cast iron and steel.

  • Deep-hole drilling from 6 x D up to 30 x D
  • To a depth of 800 mm
  • To a bore diameter of 75 mm
  • Approx. 100 tools per component
  • Surface qualities up to Rz < 4
  • Multiple fixture settings and angled bores are possible
  • 0.2 mm feed

Not only that, but on a joint basis with HELLER and Knoll Maschinenbau, we devised a new energy-efficient concept. As a result, all new machine tools are now equipped with energy filters. This not only reduces energy consumption. It also enables pressure to be monitored reliably. This helps to prevent tool breakage and to increase feed rates.

Processing

Final machining for a gleaming finish

Although our production process is almost entirely automated, a great deal of skill and experience is required when it comes to deburring the control blocks. No fewer than 14 employees are entrusted with the task of deburring our products manually, and with endoscopic inspection of bores, which can measure up to 800 mm in depth. On request, we can also perform thermal deburring of the control blocks.

Incidentally, after every fixture setting in the machining centers, the control blocks are mechanically washed and dried to eliminate any production residue reliably. With deep bores, we also employ a high-pressure lance for cleaning purposes.

Last but not least, the control blocks can receive further surface enhancement. Examples of this include painting, anodizing, galvanizing, nitro-carburizing, oxidizing and zinc-nickel plating. For these operations, we collaborate with highly skilled external specialists.

Assembly

Perfectly installed and fully inspected

On request, we can supply your control blocks fully assembled with screw-in and surface-mounted valves, screw connections, pressure switches and measuring ports etc., all sourced from leading manufacturers. It is also no problem to integrate units. To ensure that everything functions perfectly, we take charge on your behalf of dependable testing of prototypes, control blocks and complete systems. Which means that you can immediately start to use your control blocks and systems productively.