Line boring machining
Line boring repairs wear and damage mainly to bearings, mounting holes, and shafts where accuracy is important. Repair methods include welded overlay line boring finishing and oversize machining followed by bush insertion finishing, etc. For items that are difficult to disassemble and take out, on-site machining is performed.
We repair bearings for ships, construction machinery, etc. One project that requires particular skill is the boring of aluminum ship propeller bearings. Since the hull material is almost exclusively aluminum, the ship expands with changes in temperature. Therefore, centering work is performed late at night when the temperature of the hull settles down. In addition to requiring high machining accuracy, the hull temperature and ambient air temperature are also regulated, so the work must be performed under limited conditions.
Facer machining
Facer machining is a process to remove the surface of a flange when distortion or corrosion has occurred on the flange surface. We offer facing services for water jet mounting surfaces on new ships due to heat distortion after welding, as well as for corroded flange surfaces on gun batteries and large facilities and equipment.
Maintenance for offshore drilling excavator
We maintain and service excavator engines and equipment used in the drilling of oil and natural gas wells (sei).
The excavator engines include engines for drawworks to drive the drill and engines for mud pumps used in equipment to separate sludge discharged during drilling, and we overhaul and maintain both types of engines. Working at sea is a demanding environment with limited tools and materials, but we have been able to handle this work throughout the country.
Engine overhaul
We are involved in the overhaul of a wide variety of engines, including large buses, ships, trucks, construction machinery, special vehicles, gantry-type self-propelled cranes, and generators. We can also perform incidental work to engine overhaul, such as thermal spraying and polishing, in an integrated manner.
Older engines are difficult to work on because of missing parts, broken bolts, and damaged threaded holes, but since we also specialize in machining and welding, we can repair and modify them in anticipation of parts fabrication. In addition, products that are painstakingly painted receive high praise upon delivery.
Crankshafts
We manufacture new crankshafts for heavy machinery, ships, automobile engines, compressors for industrial machinery, press machines, etc. We also repair and rebuild all kinds of crankshafts.
Worn journal parts are machined by automatic flasking machines and thermal spraying equipment, and rough machined and polished by lathes, grinders, and polishers in an integrated production system. Our crankshaft grinding machine is capable of machining large crankshafts up to 4 m in length.
Cylinder heads
As cylinder heads continue to be used, heat causes distortion and corrosion on the head surface, and the valve area is worn and damaged by the opening and closing motion. First, pneumatic inspection is performed for cracks, and dents and distortions are inspected. Distortions on the head surface are milled and polished, and valve sinking and guide clearance defects are regenerated by seat ring grinding and replacement.
We also specialize in cylinder heads for large, multi-cylinder engines and can work on individual cylinder heads.
Cylinder block
Among the parts that make up the engine, the cylinder block plays a central role. Boring is used to repair the inner surface of cylinder blocks that have been damaged due to "seizure" or "hugging" caused by oil film loss or water leakage. If the damage is severe, we oversize the inner surface and bore. We manufacture sleeves and replace the sleeves into the cylinder block to restore the inner surface.
We also perform line boring of the cylinder block main journal where the crankshaft is installed. In this work, a shaft is passed through the bearing in the cylinder block, and the holes in the bearing, which normally have 3 (2 cylinders) to 7 (6 cylinders) locations, are drilled as one line. Inspect the main journal for misalignment, measure the housing inner diameter dimensions, and check for gaps and cracks in the cap joints.
If there is excessive wear, it is corrected by weld overfilling and shaving to the dimensions specified by the manufacturer. We can handle large buses, ships, trucks, construction vehicles, special vehicles, gantry cranes, generators, and other small to large items.
Axle shaft periodic maintenance
We perform total maintenance of axle shafts, which are undercarriage parts for large trailers that transport steel products within the premises of steel mills. We propose and perform periodic maintenance in preparation for customers' emergencies. We can also provide an integrated in-house system for the machining of axle overlay, fabrication of brake drums and special hub bolts, drum brake tensioning, and other small parts.
Components lot Production
We manufacture mass-produced products such as collars, retaining plates, and various hardened pins. Having been involved in the repair of large trailers for many years, we have accumulated a great deal of data on child parts. Combining this know-how with customer requests, we design and manufacture products with improved usability and safety measures.
Trailers in steel mills operate 365 days a year, so stopping a vehicle due to breakdowns can cause serious damage. We design and manufacture parts that not only prevent breakdowns, but also enable quick recovery in the event of a breakdown.
Heavy duty shelf
We manufactured heavy shelves exclusively for the factory. company A considered using commercially available shelves because space had become limited due to the flat placement of large parts such as engines and undercarriage parts for large trailers. However, there were no shelves that could accommodate the high weight items, so they asked us to do the job for them.
The shelves, which were designed and manufactured after measuring the dimensions of each part and calculating their strength, could accommodate all of the inventory, and by utilizing the factory space without waste, it also led to an increase in work efficiency.
Manufacture special tools and jigs.
We manufacture punching and extraction jigs for bearings, oil seals, etc. for large trailers that cannot be supplemented by general-purpose tools.
We were asked to manufacture special tools and jigs for large trailers, which could not be made up with general-purpose tools. We received a request to manufacture special tools and jigs. We measured the target parts and related parts, interviewed the customer about their intended use, and manufactured the optimal tools and jigs. The product was highly evaluated for its contribution to worker safety and increased work efficiency. Since then, we have received regular requests for replacement and remanufacturing of parts due to damage, and for strengthening of the product.
On-premises equipment maintenance
We utilize the strength of our in-house integrated system to perform "on-premises equipment maintenance".
We provide total maintenance, modification, and improvement of various facilities that are in operation 365 days a year, including repair and maintenance of large mobile gantry cranes, fabrication of safety fences, on-site welding work, overhaul of railroad track switching switches called ruts, and overhaul of generators and other packages and engines. We offer total maintenance, modification, and improvement services.
Repair of machine parts
Hydraulic cylinders are used in many fields, including large construction machinery, ships, and vehicles. From overhaul of hydraulic cylinders such as replacement of packings to replacement and re-plating of cylinder rods when they cannot be reused due to corrosion. We design, draft, and manufacture new packing cases and pistons to replace the packing and various seals that are no longer genuine with commercially available products.
We are often consulted by customers who are troubled by the inability to disassemble the packing case, and we sometimes perform the shaving of the packing case that does not loosen. In such cases, we also manufacture new packing cases, so our customers can rest assured that their requests will be met.
Advanced Ground Systems Engneering product Service Center
2022, we have been contracted as the only service center in Japan for Advanced Ground Systems Engneering (USA).
AGSE, founded in 1973, is a world-leading developer and manufacturer of innovative aircraft ground support equipment and tools.
The agreement recognizes our sales capabilities in aircraft ground support equipment and our technical capabilities in maintenance and servicing.
We are now able to repair and maintain aircraft ground support equipment and tools manufactured by AGSE, and we repair engine stands that carry aircraft engines.
GSE aircraft maintenance equipment
We repair and maintain not only our products, such as tobars, dollies, and maintenance workbenches, but also equipment from other companies. Qualified personnel inspect items such as magnetic testing (MT inspection), penetrant testing (PT inspection), deterioration and wear of parts, and checking operation and function. Replacement parts are checked by the customer, and repairs and maintenance are performed. For large products that are difficult to transport, we can also provide on-site work.
Since we have manufactured many GSE aircraft maintenance equipment, we have abundant drawing data and know-how, and can propose repair methods and solutions at an early stage.
Aircraft wheel
Aircraft wheel maintenance is one of our major repair items, with over 1,000 pieces repaired each year. We oversize the defective parts of aircraft wheels, press-fit bushings manufactured in-house, and then re-machine them to the proper hole dimensions.
We also repair the holes called "lug holes" where the torque bar of the heat shield, a component that prevents the conduction of high heat generated during braking, is installed. This process is very nerve-wracking because the holes are small and the machining area is narrow, and the dimensional tolerances are in microns (μm).
Reverse engineering
Many customers are troubled by the fact that they cannot request repairs or manufacturing due to a lack of drawings for facilities, equipment, and parts that have been manufactured for a long time. In order to respond to such requests, we are working on reverse engineering by utilizing our 3D scanner and the sketching capabilities of our design department, which we have cultivated over many years.
We measure the dimensions of used parts, create drawings, and manufacture the parts. However, used parts are subject to wear and tear, and if the dimensions are measured and drafted as they are, there is a possibility that they will deviate from the dimensional tolerances and no longer be viable as products. In such cases, it is necessary to measure not only the part to be manufactured but also all related parts to determine tolerances. This process is extremely difficult, but it is one of our specialties.