Gallagher Fuel Systems' explosion proof box

Gallagher Fuel Systems (formerly PEC) have been manufacturing Fuel Pumps for over 70 years, and are leaders in the Australasian fuel dispensing system market, an industry which is highly regulated due to the obvious health and safety implications if something goes wrong. This is why, when Gallagher Fuel Systems needed an Explosion Proof Box for inside their fuel pump, they looked to AXIAM as a trusted supplier to meet their needs. Not only was AXIAM able to provide the box and lid to a level which surpassed all regulatory requirements, they also provided all documentation to prove it.

Being an explosion proof box, the normal level of porosity (small air pockets) which are left in the casting process was simply not good enough for this casting. Knowing this, the AXIAM team undertook a series of statistical trials to determine the optimal operating parameters for this product and then followed these trials with a validation process on the CNC Machines. Through this process AXIAM have been able to ensure that units were well above average in the limitation of porosity and are cast in the most efficient and effective manner possible.

Extensive quality testing is also carried out throughout the manufacturing process to ensure conformance to a specialty set of high standards. The completed units are then packaged as a box and lid set so that they arrive at Gallagher Fuel Systems ready for assembly along with their certificate of conformance for each batch run.

Through this attention to quality, Gallagher Fuel Systems can be assured that their products are manufactured to the highest standards possible.

Customer: Gallagher Fuel Systems Ltd

Product:
4G98150 - EXD enclosure set (case and lid). An explosion proof box which houses the electronic equipment within fuel pumps to reduce risk of fuel explosions.

Market:
Local / Export – gas and oil / electronics Industry

Project leaders:
Steve Callaghan, Dean Kensington, Ian Churchouse,

Product statistics:
Case: 267.5mm x 192.5 x 67mm
Lid: 267.5mm x 192.5mm x 18.5mm
Case: 2.96Kg, Lid: 1.84Kg finished weight
LM9 alloy
42 machined holes
29 separate critical dimensions

Processes:
Low pressure tilt gravity casting
Trim overflow
CNC machine
Handwork to clear machining burrs
Pack and dispatch as case and lid set

Project overview:
Initial enquiry received
Gravity casting parameters and alloy testing
Designs and drawings were completed
Tooling commissioned
Tooling approved and tested
Process designed and documentation created
Product testing and sign off completed
Ongoing supply

Technical challenges:
Nominal 20mm+ thick wall section
Requirement to have minimal or no porosity
Safety and manufacturing standards
Surface finish requirements on machined faces