Department of Defense (DoD) Custom Electrical Enclosure CASE STUDY

Critical Applications Demand Adherence to Specifications

Fox Valley Metal-Tech is a trusted precision metal fabricator, delivering highly complex electrical enclosures for naval and defense vessels. By working collaboratively with trusted partners, we ensure compliance to specifications and deliver projects that meet the high standards of the U.S. Department of Defense.

Gerald R. Ford-class Nuclear Aircraft Carrier

Fox Valley Metal-Tech constructed several versions of complex, highly engineered electrical enclosures for Ford-Class nuclear powered aircraft carriers. The enclosures were built for a high-profile corporation in the energy and defense industries for use on the following United States Navy vessels.

• CVN78: Gerald R. Ford
• CVN79: John F. Kennedy
• CVN80: USS Enterprise
• CVN81: Dorris Miller

These precision enclosures contain the critical electronic devices that power the electromagnetic aircraft launching system (EMALS) and the advanced arresting gear (AAG) system.

The Story

Fox Valley Metal-Tech received a call from the high-profile corporation requesting a proposal for EMALS electrical enclosures to be used on the Ford-Class nuclear aircraft carriers. The prospective customer noted that Fox Valley Metal-Tech was recommended by the shipyard that was building the vessel. Their recommendation was based on hundreds of other electrical enclosures made by Fox Valley Metal-Tech for the power distribution system that was being installed on the ship at the time.

The prospective customer visited Fox Valley Metal-Tech to review the facility, capabilities, and skills of its AWS and NAVSEA certified employees. Fox Valley Metal-Tech provided a proposal for the enclosures needed for EMALS and was awarded half of the order (the customer planned to award the other half to another supplier for scheduling purposes). The enclosures were to be manufactured to extremely tight tolerances using O-temper annealed aluminum which is soft and prone to movement when being machined, welded, or when loads are applied.

The electrical enclosures were large in size, measuring approximately six-feet wide, nearly four-feet deep, and seven-feet high. The alignment of internal electronic devices needed to be within 0.010-inch to ensure both engagement and parallelism for maximum performance and energy efficiency. Misalignment and variance would result in lowering power output to unacceptable levels.

The Solution

Fox Valley Metal-Tech engineered a customized manufacturing solution utilizing custom welding fixtures, specialized jigs, precision inspection tools, and rigid shipping fixtures and pallets. Detailed manufacturing drawings were made to ensure piece parts going into the construction of sub weldments accommodated weld shrinkage and provided machining stock. A custom machining head was manufactured to machine holes into tight locations, which had to be done after the enclosure was completely welded together.

The precision inspection tools simulated the installation of the critical electronic devices to ensure proper assembly could be achieved. The rigid shipping fixtures ensured that critical locations and relationships of mounting holes, slides, and rails were maintained during the transportation of the enclosures’ 850-mile journey from Wisconsin to the customer. The soft O-tempered aluminum used to manufacture these enclosures was known to shift from the vibrations and bumps in the road.

The Results

Fox Valley Metal-Tech delivered the highly complex precision electrical enclosures to the customer’s facility exactly to specifications. The installation of the electronic devices went perfectly and was completed in just 25% of the planned time. Previously built enclosures required extra fitting and shimming time. With the Fox Valley Metal-Tech manufactured enclosures, the extra time to install the electronic equipment was eliminated.

As a result of Fox Valley Metal-Tech’s high quality and skilled workmanship, a visit was made by the customer’s Senior Leadership to see for themselves how this type of precision was achieved and to communicate that Fox Valley Metal-Tech would be awarded the second half of the required enclosures. The completion of the program went very well and Fox Valley Metal-Tech received a letter of appreciation for providing fabrications of the highest quality and for completing the work two months ahead of schedule.

Conclusion

Unrivaled craftsmanship, quality, and attention to every detail is why defense and commercial clients consider Fox Valley Metal-Tech to be one of the best precision metal fabrication companies in the country. Have a challenge that other fabricators have had difficulty overcoming? Contact our team of experts today.

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