PRECISION ENGINEERING
Production process
“ We manufacture over 3000 part numbers and ship hundreds of thousands of units every year . The manufacturing process starts in two separate areas ; we have the hollow section division and the sheet steel division . The sheet steel division runs the very latest in technology with laser cutting and automation . From here , we pass the products through press braking and the weld nut application , then it ’ s off to the work-in-progress holding area ,” explained the CEO of Tow-Trust Towbars , Tom Miller .
The sheet steel division is home to various technologies from Bystronic ; the area boasts three Bystronic press brake machines ( the Xpert 40 , Xpert 80 and Xpert 200 ) lined up next to a 4kW Bystar Fiber 3015 and a new 12kW ByCut Smart Fiber 3015 laser cutting machine . Both machines are continuously supplied with material from each Bystronic ByTrans 3015 Extended automated sheet metal loading facility ( designed to minimise operator intervention ).
The company also has a ‘ hollow section ’ division . Discussing this area , Tom Miller continued :
“ This department also runs the latest technology . Here , we have the automated Bystronic ByTube 130 for cutting round and square tube material stock and alongside this is a custom-built AMOB CH120 semiautomated machine for tube bending . This gives us complete control over our product , which is essential as we work to very tight tolerances and require the ultimate in quality .
“ When all the products have passed through our manufacturing phase , and the hollow section and sheet steel division complete their parts , components are then moved to the work-inprogress area . Here , we construct sub-assemblies and undertake our quality control process . This feeds our welding shop where we have ten manual welding bays for small intricate parts and low-volume production parts . We also have five robotic bays for high-volume production ,” he continued .
Laser cutting on the ByStar Fiber .
CEO of Tow-Trust Towbars , Tom Miller .
The Bystronic ByTube 130 in operation at Tow-Trust .
Components being formed on the Bystronic Xpert 80 press brake .
Design , test , approval and coating
Above the production shop floor is the company ’ s Design Centre and Test Division , where the Tow-Trust team works closely with customers , vehicle manufacturers and its network of national dealers .
Alluding to the role of this department , Tom Miller added : “ Our in-house design team will always start by applying for the vehicle
ISMR March 2025 | ismr . net | 49