1. Product Design & Process Planning3D Design & Simulation
Complete 3D modeling of the entire machine—including frame, lift arms, and hydraulic system—using software such as SolidWorks or Creo (Pro/ENGINEER).
Perform structural analysis (FEA), motion simulation, and interference checks to define material specifications, weld requirements, and tolerance standards.
Bill of Materials (BOM) & Process Planning
Generate a complete BOM, clearly identifying domestic and imported components (e.g., engine, pumps, valves, motors).
Develop detailed process documentation for welding, machining, assembly, painting, and inspection standards.
Tooling & Fixtures
Design and manufacture dedicated fixtures, including frame welding jigs, lift arm fixtures, drilling fixtures, and assembly platforms to ensure consistency and repeatability.
2. Structural Fabrication (Frame, Lift Arms, Platform)
2.1 Material Cutting
Materials: High-strength low-alloy steel such as Q345B and Q690.
Processes: Laser cutting, plasma cutting, or flame cutting with tolerance controlled within ±0.5 mm.
Components: Frame side plates, bottom plates, reinforcements, lift arm plates, brackets, and mounting plates.
2.2 Bending & Forming
CNC press brakes are used to form U-shaped, L-shaped, and box structures, ensuring dimensional accuracy and angle consistency.
2.3 Welding (Critical Process)
Processes include CO₂ gas shielded welding, submerged arc welding, and robotic welding.
Frame: Fabricated from plate weldments, often integrated with the hydraulic oil tank structure.
Lift Arms: Typically double C-channel design with welded bushings; strict requirements for symmetry, minimal distortion, and defect-free welds.
Welding distortion is controlled through proper fixturing, segmented welding, balanced weld sequences, and post-weld stress relief (thermal or vibratory).
2.4 Machining & Finishing
CNC machining (boring, milling, drilling) ensures coaxiality of pivot bores and flatness of mounting surfaces.
Grinding and deburring of weld seams, followed by non-destructive testing (NDT) such as magnetic particle or ultrasonic inspection.
