Thermal and Structural Parts for Rail Auxiliary Power Supplies

Requirement

The customer builds auxiliary power supplies for rail vehicles. Power devices sit on a large base plate inside a tight enclosure under continuous vibration. Their previous supplier struggled to hold flatness on the larger plate, so contact was uneven after assembly, and the mounting bracket showed signs of loosening in vibration testing.

Our approach

We split the plate: the power zone and the large face are machined separately and then combined, which limits distortion from part size. The large face is milled and flatness-corrected, with contact steps left where the devices sit. Brackets were thickened, ribs added at bolt positions, and tapped holes checked piece by piece with go/no-go gauges.

Delivery and inspection

First batch of 20 sets with flatness and thread records, packed in layers to protect the large faces.

Project summary

Device contact is now even and no loosening appeared in vibration testing. With the split design, later models only need one section changed instead of the whole plate.