Every efficient delivery represents a mutual commitment between customer trust and team capability.
In the User Story column, we document the real-world challenges and solutions encountered on the factory floor, uncovering the "Gesac Solution" behind complex manufacturing problems.
【This Issue ID：No.1】
Project Keywords: Complex Structural Components / Deep-Cavity Thin-Wall Features / Fast Cycle Time / Turnkey Solution
Collaboration Partner: FANUC
Delivery Timeline: 2 Months
The electric control box for new energy vehicles is not only the core system control component but also a critical "precision challenge" in the manufacturing process.Recently, the Gesac Solutions Project Team successfully delivered a complete machining line for these electric control boxes.From process design to tooling development, from trial cutting and machine commissioning to formal line startup – the entire project was completed in under two months.Through balancing cycle times across all operations, the line achieves a stable output of one qualified part every 77 seconds in batch production.
Annual production requirement exceeding 200,000 pieces; target cycle time ≤ 80 seconds/piece (including loading/unloading).
Hole diameter precision controlled within ±0.01mm; surface roughness Ra ≤ 1.2μm.
Overall delivery timeline targeted within two months.
Parts are die-cast ADC12 aluminum alloy. Key processing challenges include:
Deep-cavity structure + thin-wall areas demanding stringent vibration and deformation control.
High density of threaded holes and mating holes requiring exceptional dimensional consistency.
Die-cast material tendency to stick to tools (built-up edge - BUE), impacting surface finish consistency.
Process Design
Full line layout: 3 operations across 21 machines.
Simulation ensured synchronized cycle times and minimized idle/waiting time at all stations (loading/unloading included).
Tool Development & Testing
A total of 48 cutting tools were designed, with over 95% featuring custom structures;
Critical machining zones utilized combined solutions including PCD milling cutters, compound forming tools, and multi-flute step drills;
All tools underwent pre-deployment runout control and lifespan validation, achieving tool runout ≤ 0.003mm.
Development & Testing
The complete process routing underwent collaborative UG + Vericut simulation validation;
Over 10 machine optimization iterations were conducted during trial cutting, addressing four critical parameters: hole position, dimensional accuracy, surface roughness, and cycle time;
A full-line continuous operation test was completed pre-deployment, with the first-off article during formal trial production achieving immediate customer acceptance.
Actual Delivery Results
Customer Feedback
"Once the cycle time stabilized, the debugging pressure on the entire line significantly reduced." - Project Engineering Lead, Customer Side.The line is currently running smoothly in batch production.The customer is now collaborating on several additional structural component production lines.
FANUC supplied the equipment. Our synergistic approach ensured:
🔧Deep simulation for matching machine capabilities with process cycle times.
🤔Concurrent line commissioning, reducing deployment time.
🧑🤝🧑Highly efficient collaboration, establishing a replicable turnkey project model.
This successful full-line delivery exemplifies Gesac's "Efficient & Replicable Solution Delivery Capability."We remain committed to breakthroughs in processing complex structural parts, collaborating with partners across the value chain to build a more efficient intelligent manufacturing ecosystem.
400-998-6858
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