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أداة رفع هيدروليكية بزاوية 90 درجة من جرادين 10T: تأمين الأصول عالية القيمة في أدوات صناعة السيارات

نظرة عامة على العميل

اسم المشروع: Gradin 10T Hydraulic 90° Upender for Automotive Tooling Turnover

العلامة التجارية المتعاونة: SIEMENS,SMC,REXROTH,CHINT / DELIXI

موقع التنفيذ: Zhejiang, China

وقت التعاون: 2026.4.25

In the high-precision world of automotive stamping, a 10-ton die (mold) is more than just steel—it is a multi-million dollar asset. A leading automotive component manufacturer faced a critical bottleneck: their existing flipping process was erratic, causing micro-vibrations that threatened the calibration of sensitive tooling. Gradin engineered a Bespoke 10-Ton Hydraulic 90° Upender, delivering a “Zero-Impact” flipping solution that guarantees both operator safety and asset integrity.

التحدي والحل

تحديات العميل

The client’s production floor was suffering from “Operational Anxiety.” Their legacy mechanical flipping methods were characterized by:

  1. Kinetic Shock: Sudden movements during the 45-degree transition point, which risked internal hairline fractures in expensive molds.

  2. Regulatory Pressure: Australia’s strict WH&S standards meant any manual intervention in the 10-ton “Crush Zone” was an unacceptable liability.

  3. Efficiency Drain: A process that should take 2 minutes was taking 15 minutes due to excessive safety precautions and stabilization time.

الحل المخصص لـ GRADIN

Gradin redefined the client’s workflow by moving beyond a standard machine to a Bespoke Safety System:

  • Advanced Proportional Hydraulics: We implemented a custom hydraulic circuit that ensures a soft-start and soft-stop. The motion is so fluid that a coin standing on its edge on the platform would not fall during the 90° transition.

  • V-Groove / Flat-Bed Hybrid Platform: To accommodate both cylindrical coils and rectangular molds, the platform was custom-machined, providing “Positive Locking” for the load to eliminate any chance of sliding.

  • The “Safety Shield” Logic: Integrated with dual-hand control stations and perimeter light curtains, the system ensures that the 10-ton force is only unleashed when the environment is 100% secure.

المعايير الفنية والعلامات التجارية الداعمة

المعلمات الفنية

الميزة المواصفات الفنية
Max Loading Capacity 10,000 kg (10 Metric Tons)
زاوية الميل 0° – 90° (Precision Controlled)
Cycle Time 30 – 50 Seconds (Adjustable)
Hydraulic System Dual-Cylinder Synchronized Drive
الامتثال للسلامة CE / AS 4024 (Australian Safety) / ISO 12100
Structural Build Reinforced Q345B Carbon Steel
معالجة السطح High-Visibility Safety Yellow / Anti-Slip Coating

العلامات التجارية الداعمة

تعتمد ماكينات الإمالة لدينا على مكونات ذات علامات تجارية محلية ومستوردة ممتازة للتحكم الكهربائي، والهوائي، والهيدروليكي، والميكانيكي.
  1. Electric Control Components

    أجزاء عالية الجودة تضمن التشغيل الدقيق والمستقر

    -SIEMENS: جهاز التحكم المنطقي القابل للبرمجة (PLC)، العاكس، الأجزاء ذات الجهد المنخفض

    •MITSUBISHI: Auxiliary drive and signal feedback parts

  2. Pneumatic & Hydraulic Components

    ضمان التقليب الثابت وسعة التحميل العالية

    -SMC: الأسطوانات وملحقاتها الهوائية

    -REXROTH: الصمامات الهيدروليكية ومحطات الضخ

  3. Mechanical Transmission Parts

    هيكل متين يتيح التشغيل السلس

    •HIWIN: Auxiliary positioning guide assemblies

    •NSK: High precision rotating pivot bearings

  4. Low Voltage Distribution Parts

    -تشينت/ديلكسي: القواطع والمفاتيح الكهربائية

    -إيتون: مكونات السلامة والتوزيع

تنفيذ المشروع وإنجازاته

تفاصيل التنفيذ

التنفيذ والإنجازات

For a high-value automotive tooling manufacturer in Zhejiang, China, we provided a customized 10-Ton Hydraulic 90° Upender System. This all-in-one tilting solution integrates stable heavy-load flipping and conveyor pre-docking functions in one unit, replacing disjointed crane-assisted manual turnover processes. It effectively solves the problems of fragmented workflow, high-value die collision damage and low production efficiency in automotive die machining.
  1. All-In-One Integrated Process Optimization

    Traditional automotive die production requires overhead crane cooperation plus manual auxiliary positioning for vertical-to-horizontal turnover, resulting in frequent workpiece shifting, long cycle time and repeated positioning correction. This integrated upender realizes fixed stable 90-degree flipping and seamless conveyor docking in one station. It eliminates intermediate hoisting handling links, streamlines the production process and greatly improves operational continuity.

  2. Greatly Improved Production Efficiency

    The original segmented hoisting operation mode leads to long waiting and switching time, restricting overall die processing output. The synchronized dual-cylinder hydraulic tilting and PLC fixed-angle control work coordinately to achieve one-stop die turnover. It improves comprehensive production efficiency by over 82%, shortens the forming and processing cycle of automotive stamping dies, and significantly increases daily production volume.

  3. Stable Processing Accuracy & Zero Workpiece Damage

    Crane-assisted irregular flipping easily causes expensive die displacement, edge chipping and structural deformation, leading to huge economic loss from scrapped high-value tooling. The heavy-duty integrated structure features stable load-bearing and balanced hydraulic tilting. The fixed backrest baffle avoids die sliding during rotation, realizing precise angle positioning and zero damage to automotive tooling workpieces, effectively reducing waste and rework costs.

  4. Remarkable Labor Cost Reduction

    The traditional process requires multiple workers to cooperate in crane commanding, die binding and auxiliary turnover. This automated integrated equipment supports single-person operation for the whole process. It reduces labor dependence, avoids efficiency differences caused by manual operation, and maintains stable and high-frequency production output.

  5. Heavy-Duty Customization for Automotive Workshop Working Conditions

    Tailored for the heavy-load, metal-dust floating working environment of automotive die factories, the whole machine adopts thickened steel structure and wear-resistant & dust-proof treatment. The 10-ton rated load perfectly adapts to the weight of conventional large automotive stamping components. The pit-free ground-mounted design fully meets the factory’s no-foundation modification requirement and high-strength continuous operation demands.

الفوائد الإجمالية للمشروع

After equipment commissioning and operation, the client’s automotive tooling production line achieved 82%+ efficiency improvement, fewer defective high-value dies and reduced labor investment. The whole production process realized integrated, automated and standardized handling, greatly improving production capacity and core market competitiveness of the factory.

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