China WEYO AUTO TECH Company Cases

On-Site Excellence: High-Volume Valve Repair & Retrofit at Ningbo Xusheng Delivering Rapid Turnaround and Precision Upgrades for a Leading Automotive Component Manufacturer     Introduction Ningbo Xusheng Auto Technology Co., Ltd. (603305.SH), a prominent supplier to global electric vehicle manufacturers, relies on highly automated production systems. The performance of hydraulic systems—especially critical proportional and servo valves—directly impacts production efficiency and part quality. When faced with frequent valve failures and prolonged downtime, Xusheng partnered with our team for a large-scale on-site repair and retrofit initiative. The Challenge Xusheng’s die casting and machining lines use numerous high-performance valves that control precision movements. Over time, these valves developed issues such as: Drift in proportional pressure and flow control Slow response and inconsistent clamping/injection performance Contamination-induced failures and seal degradation Long lead times for replacement parts affecting production schedules The client needed a solution that would: Minimize machine downtime Restore valve performance to OEM standards Introduce modernized components for longer service life Provide on-site technical support for minimal disruption Our Solution: On-Site Valve Repair and Retrofit Program Our engineering team executed a full on-site service campaign at Xusheng’s facility, including: 1️⃣ Diagnostics & Evaluation Systematic testing of all main and servo valves in die casting machines and automation units Identification of failure root causes: contamination wear, solenoid burnout, spool corrosion, and seal failures 2️⃣ High-Volume Repair Repaired over 120 valves including: Proportional pressure valves Servo-proportional directional valves Cartridge and pilot-operated check valves Processes included: ultrasonic cleaning, lapping, recoiling, reassembly with OEM-grade kits, and full recalibration 3️⃣ Retrofit and Modernization Where appropriate, older valve models were replaced with newer-generation equivalents for better performance and compatibility Custom manifolds and mounting adaptations designed to drop into existing systems 4️⃣ On-Site Testing and Validation Each valve was tested on portable test benches simulating real operating conditions Valves were verified for: Hysteresis < 3% Repeatability ±0.5% Rated flow and pressure at 95%+ efficiency 5️⃣ Training & Knowledge Transfer Conducted maintenance workshops for Xusheng’s technical staff Delivered valve maintenance best practices and contamination control guidance Results Delivered ✅ 85% Reduction in Valve Downtime: Most valves repaired and returned within 48 hours ✅ ~60% Cost Savings compared to new valve replacements ✅ 30% Improvement in Response Time on retrofitted hydraulic circuits ✅ Enhanced System Longevity with upgraded seals and materials ✅ In-House Capability Built through training and documentation Client Feedback “We were impressed by the speed and skill of the team. They transformed our maintenance approach from reactive to proactive. Repairing valves on-site allowed us to avoid weeks of downtime and gave us more control over our equipment health.” — Maintenance Manager, Ningbo Xusheng Why Choose Our On-Site Valve Services?  

Precision Retrofit: Delivering Enhanced Control and Efficiency for an Yizumi 2500T Die Casting Machine       Executive Summary: This case study details the successful retrofit of an Yizumi 2500T die casting machine, a project led by [Your Company Name], a specialist in industrial automation solutions for die casting. By implementing a series of critical upgrades to the valve and sensor systems, we significantly enhanced the machine's performance, repeatability, and operational efficiency, delivering substantial ROI for the customer. The Challenge: The client operated an older model Yizumi 2500T machine experiencing several issues: Inconsistent Cycle Times: Due to degraded valve response and inaccurate pressure control. Quality Variations:Flaws in parts caused by imprecise injection velocity and intensification profiles. High Maintenance Costs: Frequent failures of hydraulic valves and unreliable sensors led to excessive downtime and parts replacement costs. Lack of Data:Limited sensor data made process monitoring and troubleshooting difficult and reactive. The goal was not just to repair but to modernize the machine's core control systems to achieve better-than-new performance levels. Our Solution: A Technological Overhaul by WEYO WEYO was commissioned to design and implement a comprehensive upgrade package focused on the heart of the machine's hydraulic and control systems. 1. Advanced Valve System Integration Proportional Servo Valve Retrofit: We replaced outdated standard and proportional valves with high-response, closed-loop proportional servo valves for the injection and intensification circuits. This provided vastly superior control over flow and pressure, enabling extremely precise ramp-up and profiling. Custom Valve Manifold Design:We engineered a bespoke manifold block to integrate the new valves, reducing potential leak points, simplifying the plumbing, and improving overall system cleanliness and reliability. Optimized Hydraulic Control Logic: Our engineers developed and tuned advanced control algorithms within the machine's PLC to fully leverage the capabilities of the new valves, ensuring smooth and accurate motion control. 2. High-Fidelity Sensor Upgrades: Precision Pressure Transducers: We installed high-accuracy pressure sensors at critical points—injection chamber, intensification piston, and hydraulic manifold. This provided real-time, reliable data for closed-loop control. Robust Linear Position Transducers: The existing injection and shot end position feedback systems were replaced with magnetostrictive linear displacement transducers (LDTs). These offered exceptional accuracy, repeatability, and resistance to the harsh conditions of a die casting cell. Integrated Data Acquisition: All sensor data was seamlessly fed into the machine control system, providing operators with a complete digital view of the injection process for the first time. The Implementation: Our team managed the entire project, from initial system audit and design to installation, calibration, and on-site validation. The retrofit was executed during a planned shutdown to minimize disruption to the client's production schedule. Results Delivered: The technological contributions made by [Your Company Name] yielded immediate and measurable improvements: ✅ 25% Improvement in Process Repeatability: Precise valve control and accurate sensor feedback eliminated inconsistencies in the shot profile. ✅ 15% Reduction in Cycle Time (Average): Faster valve response and optimized motion profiles streamlined the entire process. ✅ Significant Enhancement in Part Quality: Scrap rates were drastically reduced due to perfect shot-to-shot repeatability and precise intensification pressure control. ✅ Predictive Maintenance Capability:Real-time sensor data allows the client to monitor system health and address issues before they cause unplanned downtime. ✅ Future-Proofed Operation: The modernized system provides a platform for Industry 4.0 connectivity and data analytics. Client Testimonial: "The expertise of [Your Company Name] in die casting automation was evident throughout this project. Their focus on the critical details of valve and sensor technology transformed our older Yizumi machine. We now have control, data, and reliability we never thought possible from this press, all at a fraction of the cost of a new machine."* — WUXI Langxian WEYO is a technology-driven provider of automation solutions specifically for the die casting and injection molding industries. We specialize in retrofitting, modernizing, and enhancing industrial machinery through advanced motion control, data acquisition, and bespoke engineering, helping our clients achieve new levels of productivity and quality.