Manufacturing process
Plastic Working
In plastic working, the electrical equipment workpieces are shaped by means of forging, bending and pressing. The workpieces are subject to the following plastic working operations as needed: stamping and open die forging, upset forging, pressing, bending, punching, piercing, push broaching and rolling. The plastic working operations are performed by eccentric, hydraulic and friction-type presses. Then, the workpieces to be processed by hot plastic working are heated in chamber furnaces, direct furnaces, electrical chamber furnaces or in direct resistance heaters and inductance heaters.
Cutting metal plates
In cases when either the making of blanking tools is considered economically unjustified or metal plates are to be used to manufacture electrical accessories, we employ the shape gas cutting process. This operation is made using a CNC double-burner gas cutter.
Die casting
BELOS-PLP manufactures casts made from aluminium, AK9 aluminium alloy and Z41 zinc alloy. The foundry is equipped with energy-saving electrical furnaces with their melting pots made from silicon carbide. The furnaces feature a continuous measurement of the temperature of liquid metal.
Welding
Welding operations are made using high-performance inverter welders that employ a welding parameters monitoring system to produce high quality welds. BELOS is able to weld both steel and aluminium workpieces.
Tube bending
BELOS-PLP has developed the technology of tube bending to manufacture certain components of its protective electrical accessories (guard rings for HV power lines).
Machining
BELOS-PLP means a variety of machining operations, such as: turning, milling, drilling, threading. Because of the very large Company’s range of manufactured products, machining is performed using multipurpose and CNC machine tools. Operations of turning, milling, drilling and threading relate to steel, brass and aluminium workpieces.
Tool Shop
BELOS-PLP has its own Tool Shop to make tools, devices and auxiliary workshop accessories for internal purposes, including forging dies. Those latter are made using a CNC electro-erosion machine. All graphite and copper electrodes for the electro-erosion machine are developed in BELOS’ Perpendicular Machining Centre. This technology allows making forging dies to produce products featuring high quality and sophisticated shapes. The Tool Shop is also a source of welding equipment, gravity dies and metal moulds for machining operations.
Surface treatment- mechanical cleaning
All electrical accessories for power lines are zinc-coated against corrosion. The surfaces to be zinc coated are first cleaned by cut-wire shot peening with to improve adhesion. Cut-wire shot is characterized by high wear resistance and provides a well cleaned surface.
BELOS-PLP’ hot-dip zinc coating modern process is effectively protects steel against corrosion. It is one of the most efficient antioxidation methods. The workpieces to be zinc-coated are first subject to an appropriate surface treatment and then immersed in liquid zinc at the temperature of 460°C.
The Laboratory
The quality of the manufacturing processes is checked at each stage. The final stage of the complex manufacturing process includes laboratory tests and technical inspection.
All power line accessories are subject to tests in the Materials Testing Laboratory. All products manufactured by BELOS comply with the relevant Polish standards or technical specifications based on European standards.
