Most of the function-related microprecision components are manufactured by Liebherr in house. This results in extraordinary flexibility that allows us to develop and implement custom configurations to meet specific customer requirements. We can even supply precisely tailored small quantities to customers specialising in niche applications. This is made possible by strong technical know-how in the production of precision parts, decades of application experience and a high level of vertical integration.
State-of-the-art processes for the production of precision parts
Both the geometry and surface finish of parts in the micrometer range mean that precision manufacturing is a crucial step in producing high quality and durable products. For example, the geometry of a nozzle hole and its reproducible production are particularly important in ensuring fine atomisation of fuel. Even the smallest of deviations in the micrometer range can have far-reaching consequences. Liebherr therefore uses special manufacturing processes based on state-of-the-art technology at the Deggendorf site for the production of microprecision components.
Electrical discharge machining
To be able to reliably comply with tolerances of a few μm, Liebherr relies on electrical discharge machining to manufacture injector parts. This process is based on spark erosion.
Hydro erosive grinding
Liebherr has many years of experience in hydro erosive grinding at the Deggendorf site. The injector nozzle holes are rounded and the flow is adjusted precisely.
External cylindrical grinding
Components such as the nozzle or housing are subjected to external cylindrical grinding, thereby ensuring high-precision surfaces and outer contours.
Centerless grinding is a special method of external cylindrical grinding that is used to produce rotationally symmetrical components. We use it to ensure the special requirements of rotation and roundness.
Double disc grinding
Double disc grinding is used in the high-precision production of parallel flat surfaces. The efficiency of this process means that it is ideally suited for mass production.
Internal cylindrical grinding
Holes with the highest demands with regard to cylinder shape, surface and dimensional accuracy are machined by internal cylindrical grinding.
Examples of precision parts manufactured by Liebherr-Components Deggendorf GmbH.
Assembly in cleanroom
Extreme care must be taken during assembly to ensure that the high-precision components installed in common-rail systems work properly. The parts must be absolutely free of dust and grease. They are therefore cleaned in four different washes and checked for their purity class before they are further processed. The components of high pressure pumps, high pressure connectors and injectors are installed in a class 7 cleanroom only after they are acclimated, to ensure absolute precision during assembly.
For serial production assembly lines that are largely automated, all manual process steps are monitored by systems engineering. All assembly steps are designed to virtually eliminate operating errors using an intelligent quality management system (Poka Yoke).
Wide availability of parts
Large investments in modern production and testing facilities allow for the rapid start of serial production. Furthermore, the proportion of individual components manufactured in house is being continuously expanded. For maximum flexibility, the latest developments in material flow and other process flows are taken into account when setting up the plants. The wide availability of parts forms the basis for optimal, long-term customer support.