Custom Manufacturing of a Power Conversion Locker for the Transportation Industry

Power Conversion Locker
Power Conversion Locker

At Decimal Engineering, Inc., we focus on exceeding customer expectations producing products with ease of manufacturing in mind. We offer state-of-the-art laser cutting, metal forming, CNC machining, and welding services to meet any complex design challenge.

A Florida customer in the transportation industry requested the manufacturing of a locomotive power distribution locker with over 100 individual parts. This highly complex assembly required extensive alignment tolerances as well as a focus on design for manufacturability (DFM). Not only was the metal assembly to be laser cut, formed, machined, and welded, they also wanted in-house assembly and two-color painting. The part required dimensions of 42" wide by 60" deep and 72" high with tolerances of +/−.005" on the components and +/− .0015" on the overall assembly.

Our team employed a full suite of equipment for the job that included a Mazak Laser Cutter, Bystronic Beyeler CNC Press Brake, Kitamura CNC Machining Center, and several welding operations. Using cold rolled sheet metal, steel tubing, angle iron, steel channels, clear acrylic, and rubber gaskets for waterproofing, we produced 13 units within 6 weeks after initial engineering design. Our team used techniques such as slotting, tabbing, and cleco holes to ensure precise self-alignment. Each assembly was extensively tested for form, fit, and function. We were able to combine a series of complex parts into one operational assembly while maintaining stringent focus on DFM.

Ultimately our customer was pleased with our work and impressed by our ability to precisely fabricate complex custom assemblies. For more information on the work involved for this project, please refer to the table below or contact us for more information.

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Power Conversion Locker Project Highlights

Project Description
Power distribution locker used in locomotive application for Loram.
Capabilities Applied/Processes
Primary:
Laser Cutting (Both 2D & 3D)
Metal Forming
CNC Machining
Welding
Secondary:
Painting
Assembly
Equipment Used to Manufacture Part
Mazak Laser Cutter
Bystronic Beyeler CNC Press Brake
Kitamura CNC Machining Center
Welding
Overall Part Dimensions
42" Wide x 60" Deep x 72" High
Tightest Tolerances
+/- .005" on Components
+/- .0015" on Assembly
Material Used
Cold Rolled Sheet Metal
Steel Tubing/Angles and Channels
Clear Acrylic
Rubber Gaskets for Weatherproofing
Material Finish
Two Colors of Paint
In Process Testing/Inspection Performed
Form/Fit and Function
Industry for Use
Transportation
Volume
13 units
Delivery/Turnaround Time
6 weeks after Engineering
Delivery Location
Fort Myers, Florida
Standards Met
ISO 9001:2008

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