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Project Details
Industry: Manufacturing
Brand: Power Team

Overview

Manufacturing operations often require controlled, high-force pressing to validate parts after machining. A custom-engineered hydraulic shop press was implemented to deliver repeatable force application with precise measurement, supporting consistent product testing and quality assurance.

The Challenge

A manufacturer required a modified shop press to test products immediately after machining. The testing process needed to apply controlled force while providing clear, accurate measurement feedback to verify product performance and compliance.
 
Standard shop presses lacked the configuration and instrumentation required for repeatable, high-confidence testing. Inconsistent force application or unclear measurement could lead to retesting, rework, or missed quality issues.

Solution Presented

A custom-engineered 25-ton hydraulic shop press was supplied, incorporating an RT172 twin hydraulic cylinder powered by a Power Team PE172 pump. A 9042DG digital gauge was integrated into the hydraulic circuit to provide accurate, real-time force measurement during each test cycle.
 
This type of testing challenge is solved using high-force hydraulic shop press systems that combine controlled hydraulic power with precise force measurement for repeatable validation.

Results

The high-force press enabled reliable product testing immediately after machining. The solution improved quality control, ensured consistent test results, and supported efficient manufacturing workflows.
 
Based on typical post-machining testing and hydraulic press applications, the solution delivered measurable operational benefits:
• Test Cycle Time Reduction: Controlled hydraulic pressing typically reduces test cycle time by approximately 20–40% compared to manual or less controlled methods.
• Rework Reduction: Accurate force measurement and repeatability can reduce retesting and rework by an estimated 10–20%.
• Labor Efficiency: Faster, more consistent testing reduces operator time per part and improves throughput.
• Quality Consistency: Repeatable force application improves pass/fail consistency across production batches, reducing inspection variability.
• Scrap Avoidance: Early, reliable detection of out-of-tolerance parts helps prevent downstream processing of nonconforming components.

Other Applications

• Post-machining product testing
• Manufacturing quality control
• Press-fit assembly and verification
• Industrial component testing

Key Metrics

System Impact & Engineering Advancements

Performance Metrics & Key Achievements

40% 1

Faster Test Cycle

20% 2

Less Retesting

Improved Throughput

Reduced Scrap

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 1. Estimated versus manual or less-controlled testing methods on comparable post-machining applications; not a measured result. 
 2. Estimated from improved measurement accuracy with the integrated digital gauge versus standard presses; not measured here. 
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