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Air & Water Lines for High Speed Rail Cars


Hundreds of thousands of people travel daily on high speed light rail cars for business and pleasure. At Zeman Manufacturing, our reputation is based on providing the highest quality fabricated tube products available. This is why this customer put their trust in us for these critical components. Our diverse skills and ability to act quickly on complex jobs allowed us to deliver where the customer’s previous manufacturer had failed.

We started by reverse engineering the customer’s existing parts individually, which were numerous, a difficult task made necessary due to the lack of existing design drawings. This was accomplished using a Romer inspection arm; this high precision measuring device was used to measure the existing components, and also allowed us to download the programs directly to our CNC benders. Our CNC tube benders and Romer inspection arm allowed us to manufacture these parts with an accuracy of ±0.060” across 12 bends and various rotations. The capabilities enabled us to drastically cut overall production costs by reducing fixturing costs. The lines were formed from type K copper tubing with outside diameters that ranged from ¼” up to 1-3/8”. Thanks to the breadth of our tube bending capabilities and extensive tooling library, we were able to quickly manufacture over 250 new individual part numbers in less than two weeks.

A ≥50% silver braze alloy and oxy-acetylene torch were used for the assembly of copper and brass fittings. Copper tubing thicknesses and outer diameters varied widely, but our welders had the skill to easily handle all dimensional variables. Our customer would later comment that our brazing was the highest quality they had ever experienced and asked us to help train some of their employees!

All of the 250+ parts were produced in quantities that varied from 2 to 28, kitted, and then packaged in specially designed packaging prior to being shipped on a JIT delivery schedule, all of which was completed in just 2 weeks.

Despite the intimidating level of work involved and a strenuous delivery schedule, our dedication and flexibility in production made this job possible.





Air & Water Lines for High Speed Rail Cars Highlights

Product Description
Air and Water Lines for High Speed Rail Cars

Capabilities Applied/Processes
Primary:
Cutting
Bending
Brazing
End Forming
Flaring

Equipment Used to Manufacture Part
CNC Bend
Copper Tube Straightener Cut-off
Silver Braze Oxy-Acetylene Torch

Overall Part Dimensions
Length: 6 to 156 in
Thickness: 0.035 in
.049 in
.065 in type K Copper Tubing
Outer Diameter: .25 in
.5 in
.625 in
.875 in
1.125 in
1.375 in

Tightest Tolerances (+/-)
Length: .010 in

Base Material Used
Type K Copper Tube ASTM B88/B75

Industry for Use
Transportation

Volume
400 and up

Delivery/Turnaround Time
2 weeks

Delivery Location
Milwaukee, WI

Standards Met
Customer Specifications
3D CAD Drawing: ProE/Creo, SolidWorks
ISO 9001:2008

Additional Facts
Special Feature Inspection Arm Reverse Engineering
50% and up Silver Braze Alloy
Design and Machined the Tooling and Fixturing and Welding
Cutting Method : Straightener Cut-off


Zeman Manufacturing Company | Custom Metal Tube Cutting & Fabricating