Sky High Accuracy with Precision Welding Solutions

Challenges

Aligning three separate flanges accurately is hard enough. However, for this manufacturer of pit hoppers, the task was even more complex; Some of the flanges were rotated at an angle, which made them difficult to measure. Plus, the hopper needed to fit seamlessly atop a grain leg, 120–180 feet in the air.

Consequently, ensuring that the holes lined up perfectly was crucial. Even a small misalignment of just 1/16” at the flange could lead to several inches off at the final assembly point. Because of this, the team required a precision welding solution that left no room for error.

Solution

• 3D Welding table with large angles

• Custom adapter

To tackle the alignment challenge, Bluco provided a modular solution engineered for precision. First, our team designed custom flat plates to position the part so that the center of each flange aligned with the center of the fixturing angle. As a result, every opening was set on the same plane.

The custom adapter was designed to match the hole pattern on the flanges and rotates around the center of the flange. This allows for accurate positioning, no matter the angle. Therefore, the setup not only increases flexibility but also yields precise welds that are easy to repeat across multiple builds.

Result

Now, centerline alignment of the flanges happens instantly and consistently. This repeatable accuracy has eliminated the compounding errors that once complicated assembly and caused costly rework.

In fact, the success of the new modular fixture became clear the moment the millwright called during installation. “What did you change?” he asked. Suddenly, all of the difficulties he’d had before with the hoppers were gone.

The answer was simple: “We called Bluco.”

By collaborating with our experienced engineers, the manufacturer gained access to precision welding solutions that delivered measurable results. With their new modular fixture, they removed roadblocks, improved efficiency, and now can build with total confidence.