HYTOR solves customers’ challenges through 3D printing
HYTOR today consists of both HYTOR Fluid Solutions and HYTOR Tools Solutions. As an innovative, service-oriented group, innovative system solutions are designed and engineered based on hydraulics. The company HYTOR Fluid Solutions also sells process and instrumentation components, while HYTOR Tools Solutions focuses on the delivery, service, and calibration of specialised tool solutions.
Design, engineering, assembly, and testing are carried out in its own workshop. The company is also a certified service and calibration workshop for hydraulic and electric tools.
The product range includes the market’s best-quality products, meeting all safety and certification requirements. HYTOR is therefore currently certified to ISO 9001, ISO 14001, and OHSAS 18001.
Project: Counter Key
A changed need paved the way for a new development of counter-hold wrenches for bolts used when assembling nacelles for wind turbines. The concept was a user-friendly release counter-hold, which is not currently available on the market and therefore had to be created from scratch.
Technicians at HYTOR designed a prototype, which formed the basis for a 3D-print PROTOTYPING project. The design of the release counter-hold consisted of a total of 23 different components, including components such as springs, bolts, spacer and retaining rings, and rubber handles.
A MAKERBOT Replicator 3D printer was made available to HYTOR Tools Solutions by AM-HUB in collaboration with Center for Industri, so that the development and manufacturing process of the prototype release counter-hold was close to the developers.
The prototype release counter-hold (a proof of concept) for this highly complex special tool was produced in just a few days, which was crucial to the total time required to complete the development of the release counter-hold. Integrating 3D printing in the development phase made it possible to reduce the overall lead time from concept to actual tool by a factor of five. The total development cost amounted to one tenth compared with the costs of a conventional prototype-3D prototype printing compared with a prototype from a tool manufacturer.
Project: Hydraulic Tensioning Tool
A modification of the tool in question was necessary to solve an issue that arose due to lack of space.
Using a scan of the existing special tool, a 3D model of the relevant tools was immediately produced, which could then be processed and adjusted on-site to achieve the correct design for the torque-tightening task within the space available around the bolt.
The customised 3D model became a decisive factor, and thus the basis for an actual modification of the specific tool. Based on the 3D model, the tool manufacturer could modify the special tool so that it matched the given torque-tightening task.
It took one week from the problem arising at the wind turbine manufacturer until HYTOR Tools Solutions arrived at a solution, without having to make use of the manufacturer. Not only was a significant time saving achieved, but the costs of the development process were one tenth of what the costs would have been for a new special tool, modified with a risk of damage.
In this case, a MAKERBOT Replicator 3D printer was also made available to HYTOR Tools Solutions by AM-HUB in collaboration with Center for Industri
“It has been incredibly easy to work with the 3D printers; the software and materials are easy to use, and Center for Industri has provided valuable input regarding the possibilities and all the practical aspects.”
“We see strong opportunities for using 3D printing in our continued collaboration with our customers; among other things, it enables us to make product adjustments together with the manufacturer far more quickly than before.”
Results from programmes with Dansk AM Hub
- Significantly shorter lead time-specifically, by a factor of four.
- Significant reduction in costs for the in-house solution
- Shorter and more efficient approval procedure.
Value and impact for the company
With a “mobile workshop”, HYTOR Tools Solutions, with trained service technicians, is able to service the customer on-site with repair, service, and calibration of specialised tools, and can also assist customers with particularly challenging tasks, primarily within the installation and servicing of wind turbines.
On this basis, HYTOR Tools Solutions acts as the customer’s problem-solver and is ready to modify existing solutions both from the headquarters in Esbjerg and on-site at the customer.
In close collaboration with Center for Industri, HYTOR Tools Solutions has initiated two different projects within torque tightening for the installation and servicing of wind turbines.
Conclusion
Both cases have demonstrated a significantly shorter lead time-specifically, by a factor of four-enabled by prototyping using 3D printing.
Furthermore, the costs associated with the in-house solution have been reduced significantly compared with the estimated costs associated with delivery from an external supplier.
The approval procedure, both internally and externally, has been short and the process has been efficient for the partner and not least the end customer.
Two cases in which the company sees many opportunities, both due to the rapid development phase and certainly also the costs associated with the development phase. At the same time, it has helped to reinforce an already strong collaboration between all parties.
About the company
Hytor A/S
Location
Guldborgsundvej 1, 6705 Esbjerg Ø
Number of employees
23
Info
HYTOR has decades of experience in specialised tools for torque tightening.
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