Manufacturing Capacity

At present, the company has a total of 22 manufacturing processes and has the processing capacity of 109 kinds of processes required for the production process of oil cylinders. The self-made rate of parts reaches a new high. In order to strictly control the stability of product quality, core processes  and important parts are all produced internally, and the process technology has reached the advanced level in the industry.

The company introduces various high-precision and advanced production equipment from abroad to escort production and manufacturing. Now it is equipped with a series of professional production equipment for hydraulic cylinders, including metal cutting and processing, welding, heat treatment, surface treatment, electroplating, spraying, assembly and testing equipment, etc., ensuring that both production technology and efficiency, as well as product quality meet the standards, and manufacturing satisfactory cylinder products for customers.

Technical Capacity

Process Control Ability

In order to achieve the purpose of continuous monitoring of 22 manufacturing processes, the company organizes manufacturing process audits every year. Starting from five aspects of people, machines, materials, methods, and environment, the ability and effectiveness of the manufacturing process are comprehensively evaluated and verified.

In order to ensure the stable quality of products, all key special processes are produced internally, and process parameters are strictly controlled. Follow four steps of process verification, process evaluation, production approval, and process monitoring to ensure that process methods and process parameters meet the quality requirements of parts and product functions.
Process Verification: When new product trial production or production conditions change, samples shall be made according to product requirements and corresponding conditions, and PWPS shall be compiled to conduct process verification to ensure that process parameters can meet quality requirements.
Process Evaluation: Through various test methods, conduct process evaluation on samples to ensure that all performances of samples can meet relevant standard levels and product performance requirements, and verify the rationality of PWPS.
Production Approval: According to the process evaluation results, solidify the process parameters and convert PWPS into formal WPS, indicating that the product has the conditions for small batch production and can be officially produced according to WPS.
Process Monitoring: In the production process of the first few batches, monitor the production process to ensure that conditions such as people, machines, materials, methods, and environment meet the process settings and the product quality is stable.

Welding Technology
Welding technology is one of the core technologies in the production of hydraulic cylinders. Generally, the service life and performance of hydraulic cylinders are directly related to the welding quality. Advanced welding technologies and processes are adopted to ensure the welding quality of oil cylinders.

Gas Welding Technology

Friction Welding Technology
Welding Quality Control Ability
In terms of welding process evaluation, the company has a variety of testing and experimental means to fully verify the welding reliability.

Electroplating Technology
For the chromium plating process, the high-efficiency HEEF-KR and CA-2000 hard chromium plating process formulations are selected to make the surface of parts plated with more microcracks, good anti-corrosion performance and high hardness. Generally, the anti-corrosion performance can reach CASS four cycles and grade 9, and the hardness is HV900-1050. For special requirements, the anti-corrosion performance can reach more than CASS ten cycles and grade 9. In order to improve the anti-corrosion performance, there is also a better semi-bright nickel-bright nickel-hard chromium multi-layer process.
The production line is fully computer-controlled by PLC. After nine pre-treatments and five post-treatments, the coating quality is stable. Fully automatic control and low labor intensity. There is a lot of plating solution recovery and a small amount of pollutants.
The process control is in place. There is a perfect monitoring system and full-time physical and chemical analysts. According to the requirements, the thickness and size of each piece are tested on site, the plating solution concentration is analyzed weekly, and the salt spray test of the chromium plating layer, adhesion, hardness and other tests are conducted monthly.
For large workpiece chromium plating, workpieces with a length of 6 meters and a diameter within 400mm can be plated.
There is a stable and high-quality chromium plating employee team. Before taking up the post, they need to be severely trained and pass the assessment and obtain a certificate before being allowed to operate. Most employees have more than 10 years of chromium plating service.

Coating Quality Control
Hardness: Detected by Vickers hardness tester, hardness HV800-1100 (GB/T9790)
Adhesion of Chromium Plating Layer: Tested by heating (quenching) test method, and the coating does not peel off (GB/T5270)
Salt Spray Test of Coating: Placed in a salt spray test box for testing, and the cass copper accelerated acetic acid test reaches at least 64h (GB/T10125)
Porosity: Tested by the filter paper pasting method and reaches grade 9 or above (GB/T17721)

CASS Salt Spray Test	Hardness
	Surface/Cross-Sectional Tissue

Heat Treatment Technology
The heat treatment process is completed by the overall quenching and tempering equipment or the fully automatic surface induction heating equipment. Through hardness detection, tensile test, and fully automatic metallographic analysis detection, the quality requirements of heat treatment are ensured. The characteristics of Yinhua heat treatment process: Suspended heating, good uniformity, high temperature control accuracy, quenching liquid circulating and stirring, uniform cooling, controllable cooling rate, quenching and tempering metallographic structure rating ≤ grade 2, so that parts have good comprehensive mechanical properties and can give full play to the material potential. It is suitable for overall quenching and surface quenching of various shaft parts. The annual treatment of shaft parts for overall quenching and tempering is 2200T, and the surface induction quenching is 6000㎡.

Spraying Technology
Spraying is completed through a 315-meter fully automatic electrostatic coating production line or a large-piece manual coating production line. Through the detection of coating thickness, hardness, adhesion, corrosion resistance and other detection equipment, the spraying quality is ensured. The exhaust gas generated during the coating process is treated by a plasma photocatalytic integrated VOCs treatment equipment and discharged up to standard. Our company's cylinder coating adopts electrostatic spraying, and it takes 22 processes to form a film. Electrostatic spraying adopts the Kremlin mixed gas spraying technology, which combines the technical advantages of traditional air spraying and airless spraying. The two-component paint is automatically proportioned and mixed with gas to achieve perfect control of the spraying interface and generate a very uniform coating film on the surface of the cylinder. It is suitable for surface coating of various construction machinery cylinders. The maximum specification of cylinders for fully automatic electrostatic coating is Φ350×2000, and 160,000 cylinders are sprayed annually.

Production Capacity

Personalized small-quantity customization service to meet customers' diversified needs

In the field of hydraulic cylinders, we deeply understand the diversity of customer needs. Relying on advanced design concepts and exquisite craftsmanship, for personalized small-quantity customization services, we start from demand research and accurately grasp the special requirements of customers for hydraulic cylinders under different working conditions (such as complex terrain operations of construction machinery, high-precision processing of machine tools, etc.). Use professional CAD/CAM design software for personalized modeling to ensure that each customized cylinder meets customer needs in parameters such as cylinder diameter, stroke, and pressure level. From material selection (such as high-strength alloy steel, wear-resistant cast iron, etc.) to manufacturing processes (special welding and heat treatment processes), targeted planning is carried out to efficiently respond to customers' diversified needs and help customers improve equipment competitiveness in segmented fields.

Perfect employee technical ability training mechanism to improve production efficiency

To meet the continuously upgraded technical requirements of hydraulic cylinders, we have established a perfect employee technical ability training mechanism. Covering basic theoretical knowledge such as hydraulic transmission principles and mechanical properties of materials, so that employees can deeply understand product principles. For production practice, regularly carry out special skill trainings such as welding, assembly, and machining, and invite senior technicians in the industry to provide on-site guidance. Through case analysis and operation demonstrations, improve employees' practical ability. Introduce advanced equipment operation training to enable employees to master equipment such as CNC machining centers and high-precision grinding machines proficiently to ensure processing accuracy. At the same time, encourage employees to participate in industry technical seminars and advanced courses to master cutting-edge technologies in time. The improvement of employees' technical abilities effectively shortens the production cycle and improves production efficiency.

Integrate artificial intelligence technology and improve the innovation mechanism

On the road of innovation, we actively integrate artificial intelligence technology to improve the innovation mechanism. Use AI algorithms to deeply analyze massive operation data (parameters such as pressure, temperature, and vibration) of hydraulic cylinders, dig out potential performance optimization points and hidden faults, and formulate design improvement and preventive maintenance strategies in advance. Through artificial intelligence-assisted design, breakthroughs are achieved in aspects such as cylinder structure optimization and seal design. For example, machine learning algorithms are used to quickly screen out the optimal seal structure parameters to improve the sealing performance and service life of the cylinder. At the same time, AI technology empowers production process monitoring, monitors equipment operating status and product quality fluctuations in real time, automatically issues warnings and intelligently diagnoses problems, providing strong support for product innovation iteration and production process optimization, and promoting enterprises to continuously innovate in the field of hydraulic cylinders.

Lean production management system for scientific production

We have established a mature lean production management system to promote scientific production of hydraulic cylinders. In production layout, according to value stream analysis, optimize the layout of workshop equipment and workstations to achieve smooth material flow and reduce handling and waiting time. Use the Kanban management system to display production plans, progress and quality status in real time, making information in all links transparent and facilitating quick response and decision-making. Adopt the 5S management method to standardize the work site and improve the cleanliness and safety of the work environment. Introduce Six Sigma management tools to accurately analyze and control quality fluctuations in the production process and reduce the defective rate. Through continuous improvement activities, encourage employees to put forward reasonable suggestions and continuously optimize the production process to achieve efficient use of resources and enhance the comprehensive competitiveness of enterprises with a scientific production model.

Comprehensive production, supply and marketing operation mechanism

The production, supply and marketing departments regularly conduct order reviews, clarify customer requirements, confirm the arrival time of all materials, and eliminate unstable factors affecting production operations. Through the production, supply and marketing coordination meeting, preparations such as pre-production materials, personnel, equipment, and tooling are made in advance. Data on the situation affecting production collected from relevant personnel of various departments is evaluated. Actual production scheduling is carried out for planned orders through the internal mechanism of the department, and production is arranged in a reasonable and orderly manner. The rigorous order review mechanism and reasonable production, supply and marketing coordination mechanism make the production, supply and marketing operation system operate effectively and at high speed, which is a strong guarantee for production operation capabilities.