Every phase of product develepment process is based on customer-focused design. Subsystems are created for customers as co-design activity.

Designs are performed according to ISO/TS 16949 quality standards.

Design inputs are composed by customer requirements and expectations. These inputs are very important for successful design that will be done. Therefore, strong communication is set between customer and designer.

In addition to classical communication tool ,like e-mail, engineers also use Live Meeting, video conference etc. Data is transfered via FTP servers.

Recently, 3D Modeling have become an industrial standard for product design. Our R&D department uses the latest technological tools. By solid modeling, product design period is shortened and it gives an opportunity of working with customer one by one. Designed models are sent to the customer to control the products on the vehicle.

Used Programs;

3D Solid Modeling

• Pro/ Engineer Wildfire
• Catia 5

2D Drawing

• Pro/ Engineer Wildfire / Drawing
• Autocad

After the modeling, the next stage of design period is analysis. Structural, thermal, flow and system analysis can be done by the programs using finite element methods. As a result of analysis, the design is restructured and finalized for prototype production. By the aids of these programs, there is an opportunity to optimize. Optimization allows to design cost effective and robust products and to reduce number of prototypes, saving money and wasted time.

Used Programs;

Structural Analysis

• ANSYS
• Pro/Mechanica

Computitional Fluid Dynamics Analysis

• CfDesign

1D-System Simulation

• LMS Image.lab AMESIM

Manufacturing

Regarding to the customer demands, required prototype products are manufactured in CNC processing centre in accordance with defined flow process and in terms of mass production conditions. There are lots of vertical and horizontal machine with 4 or 5 axis to produce any type of prototype in our company. Further to critical characteristics of product, SPC Works ,which is done in short period, are progressed in conditions of mass production too.

Measurement

During the manufacturing, prototype components are 100% measured on operational basis. For the measurements , mass production equipments are used as possible.

Coordinate measuring machines (CMM) are able to measure the components in various sizes with 0,1 µ sensitivity. Furthermore, the surface scan, tests of corrosion and pollution are done and tread profile, mechanical an chemical specifications and material characteristics are defined. Material and heat-treatment cracks are controlled by using crack control devices. During the mass production, 13000 measuring devices are existing to measure on the workbench. Test are performed in the material laboratory, the pollution laboratory and 5 standard rooms.

Hydraulic Lift Tests

Hydralic Lift Test Machines:

At R&D Laboratory, durability test is performed on the hydraulic lifts. This is an accelerated test which simulates working conditions on the field.

Hydraulic lift is loaded over the maximum capacity and test is performed while the loads are being lifted up and down. During the test , the measurement is done in defined phases.

Every new design product must complete these tests. Moreover, the products are tested periodically during the mass production too.

Pump Tests

Pump Test Machines:

Performance and life tests are performed on the hydraulic pumps by the pump test machines in the R&D Laboratory. This is an accelerated test which is simulates working conditions over the vehicle. Tests are electronically controlled. Parameters such as oil temperature, applied pressure and pump revolution are controlled in test machine by computer. Measurement values are recorded and stored at the beginning, end, some interval of the test.

Every new design product must complete these tests. Moreover, the products are tested periodically during the mass production too.

Directional Control Valves Tests

Valf Test Machines:

By using valve test machines in R&D Laboratory, performance and life tests are performed on the directional control valves. This is an accelerated test which simulates working conditions on the vehicle. Tests are electronically controlled. Parameters such as oil temperature, applied pressure and oil flow rate are controlled by computer. Measurement values are recorded and stored at the beginning, end, some interval of the test.

Every new design product must complete these tests. Moreover, the products are tested periodically during the mass production too.

Steering Unit Tests

Steering Test Machines:

By using steering test machines, performance and life tests are performed on the steering systems. This is an accelerated test which simulates working conditions on the vehicle. Tests are electronically controlled. Parameters such as oil temperature, applied pressure and oil flow rate are controlled by computer. Measurement values are recorded and stored at the beginning, end, some interval of the test.

Tests are electronically controlled. Parameters such as oil temperature, applied pressure and oil flow rate are controlled by computer. Measurement values are recorded and stored at the beginning, end, some interval of the test.

Variation of the hand force, that depends on the pressure, are controlled in steering system.

Every new design product must complete these tests. Moreover, the products are tested periodically during the mass production too.

Fatique Tests

Fatique test devices are used for simulating dynamic working conditions of the hydraulic products.

Peak pressure is applied three times in each second over the normal working pressure to the products. The data is collected by computer controlled systems during the tests.

New design and mass products are tested periodically.