Manufacturing A Control Panel For Gas Stations
Orpak is a world leader in advanced solutions for oil companies and commercial fleets, ranging from fuel station automation and convenience store management to Automatic vehicle identification and customer loyalty.
Addressing this complicated project, we faced some major challenges:
- An extremely tight deadline.
- The need to combine various metal and plastics technologies and technical assemblies.
- Intended for the oil industry, the product has to undergo meticulous lab testing in order to comply with rigorous international fire standards.
- Many of the materials required were not available in China and had to be imported.
The Work Process
Step 1: Creating a design in order to test the probability of manufacturing and perform manufacturing review. Once both processes were approved, we could advance to locating and importing the materials unavailable in China.
Step 2: In order to achieve the high level of tolerance and close fit required from the parts in a moving robotic device, we combined various metal and plastic CNC technologies with advanced mechanical assemblies.
Step 3: Manufacturing each of the metal and plastic parts required optimal tool and machine selection. Utilizing a CNC turning center machine that provided maximum stability, we created homogeneous precision parts in the required quantity.
In order to achieve the high tolerance level required from such a product, we used a
5-axis CNC mill, enabling us to keep each part in a fixed fixture throughout the process.
Step 4: We then galvanized the product and applied a 100 micron thick powder coating layer to provide sun and wetness resistance for outdoor uses, as well as protection from vandalism and harsh environments.
Step 5: Due to the large size and heavy weight of the finished product and the sensitiveness of the control panel, we devised a custom packaging solution to ensure it reached Orpak in optimal condition.
Working closely with Orpak’s engineering, purchasing and shipping departments, our team established a smooth transmission to mass production, and supplied the product on schedule, including all the required lab tests. The end result was approved by Orpak in the first round, enabling the company to meet its deadline. The product is already in use, enabling fleet managers and gas stations worldwide to better control fuel consumption and leverage the gathered data to further improve their operations.