Manufacturing Process

PDCA CYCLE

PLAN:Establish the objectives and processes necessary to deliver results with customer requirements and the organization policies.
DO : Implement the processes
CHECK: Monitor and measure processes and product against policies, objectives and requirement for the product and report the results.
ACT : Take action to continually improve process performance.

The 3 most important features:
Improved flexibility
Binny Parabolic Springs will allow more axle movement due to their typical characteristics and lack of interleaf friction.
Improved stability
Binny Parabolic Springs have a slightly higher spring rate and in combination with special shock absorbers it will give more stability to the vehicle at all speeds, on- and off-road.
Increased load capacity
Binny Parabolic Springs are modular. Separate leafs can be added, to increase load capacity, or removed, to lower the spring rate, without compromising the structure of the spring itself.

What is a parabolic spring?
Basically a Binny Parabolic Spring is a spring that consists of two or more leaves. The leaves touch only in the center, where they are fixed to the axle and at the outer ends, where they are fixed to the vehicle. In between those two points the leaves do not touch each other as they do with conventional leaf springs.
Each leaf represents a complete spring in it's self and will act as such. To enable this the leaf is tapered, from the center (thick) to the outer ends (thin). This tapering is parabolic, it means that every centimeter (or inch) the thickness of the leaf decreases in an amount that relates to the square function of it's length.

Download Our Process Chart

Manufacturing Process:
In tune with our quality driven manufacturing process, the raw materials we use like Silico manganese spring steel of grades such as EN 45, EN 45A, EN 47, 60 Si7, 65 Si 7, Sup 9, Sup 9A, Sup 11, Sup 11A, 50 CrV4, 58 CrV4 which undergoes stringent inspection and testing procedures including chemical, metallurgical and micro-analysis to check adherence to quality standards.
Forging
Shearing, Eye-Rolling, Wrapping, Nibbling are some of the operations performed in this area

Heat Treatment

Our custom built Walking Beam furnace with strategically located burners ensures uniform heating. The heated products are then cambered in a hydraulically operated eight station special purpose drum cambering machine and quenched in a speciality quenching agent to obtain thorough hardness.
The subsequent tempering process in the conveyeurized tempering furnace develops desired levels of hardness. Transfer conveyors are used at every stage to eliminate manual handling and maintain a consistent throughput time.