Development and Design
After determining the customer’s requirements, a hydraulic circuit diagram is created first. Corresponding valves are selected. In the following step, the complete valve block is created in a 3D-CAD program, which offers us optimal possibilities for a safe and clear design. The data can be provided as a 3D file. After checking the design and installation situation, the path is clear for the production of a prototype.
CNC Machining
Control block housings are manufactured on CNC machining centers. Thanks to fast, simple programming, even small series can be produced cost-effectively. Valve screw-in bores can be produced reliably and effectively using step boring tools. Our machinery consists of four 4-axis CNC machines and three 3-axis CNC machines. In addition, we have an automatic lathe on which we manufacture small turned parts, such as components for shuttle valves.
Deburring and Cleaning
In hydraulics, it is essential that no burrs remain in the housings that could come loose. Otherwise, damage to valves and other components can occur. Burrs that cannot be removed on the machine are removed manually. In addition, some blocks are also thermally deburred. Before surface treatment, the housings are subjected to thorough cleaning. Final surface treatments for aluminum blocks are anodizing, as well as chemical nickel plating or galvanic zinc plating for blocks made of steel.
Assembly
A large part of the delivery range consists of complete hydraulic controls. Assembly is carried out with the utmost care, in compliance with the installation regulations of the valve manufacturer. All components are screwed in with the required torque. Errors are detected early by pre-assembling with the lowest torque.
Pressure and Leakage Testing
All SUN HYDRAULIK valves are subjected to an individual factory test. The housings manufactured in-house are checked according to the four-eyes principle during production. Depending on the requirement, the complete control system is also subjected to a pressure and leak test, during which the setting values of the valves are also checked. Each block is tested according to an individual test procedure that is adapted to the hydraulic control system. Finally, a test report is created.
Quality Assurance
In addition to careful assembly, checking the function, tightness and pressure resistance, the products must also be traceable. For this purpose, the products are individually marked accordingly. The manufactured housings are given the production week with an addition, via which the material can be traced back. For complete control systems, the delivery week is also embossed in order to be able to trace installed valves. Each hydraulically tested block receives an individual test number. A test report is created for each tested batch.