In high-voltage long-distance power transmission (132kV–765kV), if the quality of power fittings is poor, the entire transmission line will fail.
Cast parts have large internal dense gaps, and when exposed to wind and sun outdoors for a long time, they are prone to brittle fracture.
Forged parts: grains aligned along the stress direction, zero porosity, fatigue life 60% higher than castings.
On an entire 400kV transmission network, if one shackle fails due to breakage, it is not just the loss of one fitting, but the entire line.
| Power Fitting | Single Weight | Recommended AYANK Model |
| Shackle / U-ring | 0.3-3kg | J58KA-250 / 400 |
| Turnbuckle / Screw coupling | 0.5-5kg | J58KA-400 / 630 |
| Eyebolt / Stud | 0.2-2kg | J58KA-250 / 400 |
| Ball head / Fork joint | 0.5-4kg | J58KA-400 / 630 |
| Insulator hardware / Suspension point parts | 1-6kg | J58KA-630 / 1000 |
| Large specification dead-end / Strain clamp | 3-10kg | J58KA-1000 / 1600 |
Comparison table of J58KA electric screw press vs friction press vs CNC hammer:
| Dimension | J58KA Electric Screw Press | Double-disc Friction Press | CNC Hammer |
| Blow energy | Programmable ±1.5% | Foot-operated, ±10% | Foot-operated, ±8% |
| Energy saving | 60-70% less than friction press | High energy consumption | Medium energy consumption |
| Die life | High (no bottom dead center, no die impact) | Medium | Low (high impact) |
| Noise/Vibration | Medium | Medium | High |
| Automation integration | Easy to match with robots | Difficult | Medium |
Small power forgings = large batch + strict precision requirements + multi-cavity dies, electric screw press is the most suitable forging equipment main machine.
3D modeling according to IEC 61939 / ANSI C135 and other power fitting standards
Die flow analysis (Deform or self-simulation) to ensure filling of shackle arc, turnbuckle thread root
AYANK in-house die workshop makes pressing dies + pads, delivery 50% faster than outsourcing
Small parts (shackle/stud) → J58KA-250/400
Medium parts (turnbuckle/fork joint) → J58KA-630/1000
Large parts (strain clamp/suspension point) → J58KA-1600
Aluminum/copper alloy power fittings → J58ZKA servo direct drive (energy closed-loop, does not damage soft metals)
Common materials:
Carbon structural steel EN8 / S45C
Alloy structural steel EN19 / 41Cr4 / AISI 4140 / 42CrMo / AISI 4340 / 40CrNiMo / 30CrMnSiA
Stainless steel SS304 (06Cr19Ni10) / SS316 (06Cr17Ni12Mo2) / SS410 (1Cr13) / Duplex steel 2205
Aluminum/copper and alloys AL6061 / AL7075 / C11000 pure copper / C3604 brass / aluminum bronze / silicon bronze
Forging heating equipment (medium frequency furnace + infrared temperature measurement) to ensure grain not coarse
Galvanizing/hot-dip galvanizing pretreatment allowance reserved
Medium frequency furnace → Electric screw press → Trimming press → Graphite spraying robot → Inspection station
Six-axis robot picks up parts + die spray, one person monitors 2 machines
Cycle time reference: shackle type 10-12 seconds/die, 4 pieces per die → shift output 2500-3000 pieces
Our sales manager will design a detailed forging solution suitable for you.
100% dimensional inspection + magnetic particle testing (MT) + ultrasonic testing (UT)
Tensile/yield according to IEC 61939
Load test 120kN / 200kN according to customer requirements
| Dimension | Forging (J58KA) | Casting |
| Internal quality | Zero porosity | Prone to shrinkage cavities |
| Fatigue life | 30-50% higher | Baseline |
| Batch consistency | ±1.5% energy | Large fluctuation |
| Die life | 8000-12000 pieces | Sand mold unlimited but single piece poor |
| Long-term maintenance cost | Low (fewer broken part claims) | High |
ROI and customer benefits
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