Traditional casting was not suitable for an explosion proof box

Processes used in this case study

DESIGN:

Process design
Product design
Tool design
Engineering design
Product testing
Jigs & fixtures

MANUFACTURE:

Tool manufacturing

Injection moulding

Reaction & composite moulding

High pressure die-casting
Low pressure die-casting
Shell (cronin) casting
Sand casting
Heat treatment

Sub-supplier management

FINISHING:

Linished
CNC machined
Alodine pre-treatment
Vacuum impregnation
Vibrated
Ball burnished
Shotblasted
Clear anodised
Hard anodised
Wet painted
Powdercoated
Hard coated
Hot foil stamped
Pad printed

Q&A:

Certificate of compliance (CoC)
PPAP, PPEP

SIR - sample inspection report

Continuous evaluation & verification

CP & CPK study
CMM

Verification & testing
Environmental management (RoHS)

ASSEMBLY, PACKING & DISPATCH:

Assembly

Pack & dispatch: NZ

Pack & dispatch: Export

Surpassing regulations

Processes used

Gallagher Fuel Systems' explosion proof box

Gallagher Fuel Systems (formerly PEC) have been manufacturing Fuel Pumps for over 70 years, and are leaders in the Australasian fuel dispensing system market, an industry which is highly regulated due to the obvious health and safety implications if something goes wrong. This is why, when Gallagher Fuel Systems needed an Explosion Proof Box for inside their fuel pump, they looked to AXIAM as a trusted supplier to meet their needs. Not only was AXIAM able to provide the box and lid to a level which surpassed all regulatory requirements, they also provided all documentation to prove it.

Being an explosion proof box, the normal level of porosity (small air pockets) which are left in the casting process was simply not good enough for this casting. Knowing this, the AXIAM team undertook a series of statistical trials to determine the optimal operating parameters for this product and then followed these trials with a validation process on the CNC Machines. Through this process AXIAM have been able to ensure that units were well above average in the limitation of porosity and are cast in the most efficient and effective manner possible.

Extensive quality testing is also carried out throughout the manufacturing process to ensure conformance to a specialty set of high standards. The completed units are then packaged as a box and lid set so that they arrive at Gallagher Fuel Systems ready for assembly along with their certificate of conformance for each batch run.

Through this attention to quality, Gallagher Fuel Systems can be assured that their products are manufactured to the highest standards possible.

Customer: Gallagher Fuel Systems Ltd

Product:

4G98150 - EXD enclosure set (case and lid). An explosion proof box which houses the electronic equipment within fuel pumps to reduce risk of fuel explosions.