Rotec completes innovative remote monitoring system onboard a vessel

As equipment increases in complexity, there is a growing need and advantage to being able to monitor parts of, or a complete system remotely.

With a long held commitment to innovation, Rotec Hydraulics are the first known company in the UK to have designed, installed and commissioned Parker IoT software that remotely monitors a hydraulic system.

With the ability to be installed and remotely monitor any hydraulic system, Parker Internet of Things (IoT) technology allows a user to ensure their assets are working at full functionality by monitoring key performance indicators, such as temperature, pressure and flow.

The remote monitoring technology further benefits the user by providing vital performance feedback for preventative maintenance planning, and can monitor real time and historical data all within a simple web-based interface.

This web-based portal can be accessed worldwide and gives a further benefit of GPS asset tracking and visibility – thus aiding both security of equipment and logistical transport efficiency which in turn, can reduce fuel costs.

The innovative IoT project came to fruition following Rotec being asked by a boat manufacturer to gather information about the performance of the hydraulic system they were fitting to a new fleet of vessels. 

Because of the harsh marine environment, robust equipment was selected that meets high ingress protection. IoT modems are compact and have built in aerials allowing for a sealed solution, meeting strict IP67 ingress protection and wide temperature ranges of -30 to +75 degrees.

Multiple sensors were fitted by Rotec’s engineers to provide feedback of tank levels, oil temperatures, flows and pressures in various parts of the system.

A further enhancement was provided by adding a particle contamination device which monitors and uploads the vessel’s oil cleanliness data to the cloud. Previously hydraulic oil changes were performed on a time expiry basis, whereas adding sophistication of a real time oil contamination device now tells the customer when the oil needs to be changed rather than changing at estimated time intervals. This reduces both the cost for the customer and decreases the impact on the environment because they are now performed only when required.

The customer was particularly impressed as Rotec Hydraulics were able to code unique software and download this remotely to assist with additional logging during sea trials of the vessel before delivery for normal operations at sea. This provided additional information that has not previously been visible due to the nature of the testing preventing personnel being on board monitoring the systems from the bridge. 

The IoT can be connected to an engine ECU using standard j1939 CAN protocol to give live engine data to be able to monitor remotely. This can provide data feedback from various sensors to ensure optimal engine performance and critically, no abuse of the equipment when being used in the field.

Alerts can be set and configured to automatically send emails once thresholds are exceeded, enhancing the effectiveness of automated data upload. 

Built in Bluetooth and WiFi also allows the user to access the password protected modem locally to download logs and further enhance the remote experience. Software updates can be performed remotely over the web or by Bluetooth/WiFi to increase the functionality of the sampling controller or change data collection and upload frequency, allowing for maximum end user flexibility for the customer.

To discuss how Rotec can enhance your system monitoring, contact our Sales Team via 01823 348900 or email sales@rotec.net.

 

Minimising Downtime: Manufacturing Press Tube Replacement

Rotec’s technical team researched and implemented an innovative method to complete replacement tube pipework whilst keeping downtime to a minimum at a large car manufacturing plant in Gloucestershire.

Following damage occurrence on one of their press lines, the world-leading manufacturer required replacement Ø75×12.5 carbon steel tubes.

Traditionally, engineers would be required to remove the damaged tube in order to gather accurate measurements before being able to provide and fit replacements. The removal and installation processes would require manufacturer to shut down the machine during these times.

Downtime for a large manufacturer in the automotive industry can have huge implications operationally and financially. Always keeping the customer at the forefront of projects, Rotec’s technical team suggested using a 3D laser scanner to measure the pipework, in order to minimise downtime.

The 3D laser scanner not only meant that the machine no longer had to be turned off, but the measurements collected were incredibly accurate and minimised the influence of human error. Furthermore, the time required for Rotec engineers to be onsite removing pipes and then measuring them would be dramatically reduced – saving the customer costs due to reduced labour costs.

Once measured accurately, the design for new tubes created using CAD design software in-house at Rotec. In total, the measuring and design process was complete within 2 days.

Continuing Rotec’s commitment to utilising technologies, the tube ends were formed using the Parker HPF system, which eliminates the need for welding of the tube. Bespoke flanges were also machined to suit the formed profile of the Ø75mm tube and accommodate the bolt pattern of the existing connections. 

For more information visit www.rotec.net.

Rotec’s repair and overhaul service reduces running costs by 10% at leading manufacturer

Machine prior to overhaul
Overhaul completed, outer door refitted and ready for re-paint

Following a major failure during operation, a large flooring, MDF and OSB manufacturer asked Rotec to carry out extensive repairs on an industrial wood chipper.

Owing to the failure occurring whilst the machine was in use, the Maier Wood Chipper machine had suffered severe damage internally and so required a thorough repair and overhaul service.

After Rotec engineers stripped the machine and checked all components, it became apparent that the shaft bearing sleeves had failed, worn the housing and as the blades had come away during the failure, many internal parts were damaged and required either replacement or upgrading.

As the customer had issues with levelling up the impellor blades, Rotec checked the laser alignment and then ‘clocked’ the rear datum locating ring support pads on the machine. The support pads were found to have a 0.7mm difference in their positioning which, may have been a contributing factor to the issues leading to the initial failure. On discussion with the client, it was decided to build up the lower blocks and design and build a tool for machining the pads in-situ.

Once the chipper had been repaired, overhauled, re-painted and fitted back onsite at the customer’s facility, the client was so pleased with Rotec’s workmanship and project management that Rotec have now taken delivery of another unit from the same workshop for a complete overhaul.

The Engineering Managing of the flooring, MDF and OSB manufacturer has since reported that the overhaul and rebalancing of the machine is so good that the company is achieving a higher output rate and saving 10% on the machine’s previous running cost.

Laurence White, Business Development Manager for Rotec Hydraulics Ltd, commented;

“It has been a pleasure to be part of this thorough overhaul and repair service. Our team take pride in knowing that we have delivered a high level of workmanship and have not only helped to increase efficiency, but also have helped to reduce running costs for our client. We look forward to a long lasting relationship with our customer.”

For more information regarding Rotec’s capabilities, including the overhaul and repair service, contact sales@rotec.net or phone 01823 348900.

Chipper unit prior to Rotec overhaul

Damage caused by external conveyor belt

Damage to internal shaft

Internal damage caused during failure of blades

Modifications to front lower section to allow for outer adjustment on longer support sections, manufactured and fitted support bars

Die penetration checks on welding

Special support structure manufactured for accurate machining of the rear ring support pads

Inner bladed impellor fitted and clocked to ensure true

Outer door refitted on chipper

Chipper Completed unit back onsite at customer’s facility

Rotec Completes Machine Overhaul with the ‘Wow’ Factor

Rotec Hydraulics Ltd have delivered a machine refurbishment project with the ‘wow’ factor.

A leading manufacturer of high quality, precision tubes asked the Rotec team to assess and quote for the refurbishment of an old tube manipulation machine. The unit which had been in situ for many years, required a complete overhaul to improve efficiency and to provide quality and robust workmanship, due to regularly working with the toughest specifications in high performance alloys (including stainless steel, titanium and nickel alloys).

After removing the unit and transporting it to Rotec’s Plymouth service centre in Devon, the tube manipulation machine was stripped and inspected. Following the quoting process and being awarded the contract to proceed, Rotec’s skilled engineers carried out a thorough overhaul of the hydraulics, mechanical and electrical control system.

On completion, Rotec engineers attended the client’s site and re-commissioned the unit. All of the works carried out by Rotec were project managed by an assigned manager, as with all our projects. This allows for quality client-supplier relationships and improves communications.

Following the re-commissioning, the customer stated that they are very happy with the unit and they are impressed with the workmanship and quality of the overhaul.

Established in 1979, Rotec Hydraulics is a leading fluid power expert; providing quality design, build, installation and maintenance of hydraulic, pneumatic, electrical mechanical and electronic components and solutions to the Aerospace, Agriculture, Defence, Industrial, Marine, Transport and Utilities sectors throughout the UK and internationally. ISO 9001 and ISO 14001 certified, Rotec Hydraulics prides themselves on high operational standards.

For more information, visit www.rotec.net.

Rotec achieves Parker Certified Accumulator Service Centre recertification

100% Achilles audit _Rotec Hydraulics Ltd

Rotec is pleased to announce it has been re-certified as a Parker Hannifin Hydraulic Accumulator Service and Technology Centre.

Following successful completion of an audit process for Hydraulic Accumulator Technology and Service Centres, Rotec Hydraulics Ltd has retained its prestige as the only certified Parker Accumulator Service and Technology Centre in the South of the UK.

Parker Certified Accumulator Service Centres were established to enable the combination of industry-leading products with excellent customer service, and to deliver stress-free accumulator management with maximised performance, efficiency, and safety.

The benefits of being a Parker certified centre, in addition to Rotec’s status as a Parker Hydraulic Technology Centre, enables Rotec Hydraulics to provide integrated solutions that combine products, services and technologies. Rotec’s access to original spare parts provides tangible benefits to clients, including shorter inspection time and the reduction of complexity help to lower cost and to save time.

As added value to customers, the Rotec Hydraulics Ltd Service Centre is able to utilise the Parker Tracking System (PTS) which helps schedule accumulator maintenance, providing automated notifications on inspections and replacement parts.

Rotec Hydraulics have the knowledge, expertise and capabilities to deliver a comprehensive range of accumulator services including:

Regulatory compliance and certification

  • Hydraulic accumulator re-certification
  • Provision of tracking systems, data monitoring and recording
  • Optimising customer documentation to fulfil regulatory requirements
  • Local pressure vessel regulation
  • Audits, scheduled inspections and replacement parts

Hydraulic accumulator maintenance and pre-charging

  • Full service for just in time solutions and breakdown repairs
  • Full service for replacement and planned/preventative maintenance
  • Commissioning/testing (on-site)
  • Bladder and piston seal replacement
  • Gas pre-charge control and re-charge

System Optimisation

  • System design and improvement (including Hydraulic Power Units (HPUs) and Accumulator Racks, calculation, training and measurement)
  • Accumulator replacement

Asset Management

  • Energy and efficiency audits
  • Risk assessment and servicing of safety equipment
  • Asset condition monitoring and prognostics (sensors)
  • Legal conformity and insurance cover
  • Enabling customers to exploit the potential of Condition Monitoring and the use of Internet of Things (IoT) technology.

For more information on Rotec’s ramge of Accumulator services, contact our team.

Bespoke hydraulic ring main and multiple air blast coolers installed at leading Aerospace Engineering company

Rotec Hydraulics Ltd was chosen by leading aerospace and engineering business to complete a 3-phase upgrade project to its existing Structural Test Lab (STL) hydraulic ring main. The team at Rotec successfully completed the project on time and to a high level of quality.

A global leader in Aerospace, Defence and Security, our client is a key supplier of defence and security equipment to the UK MoD, employing over 7,500 highly skilled personnel across 7 main sites throughout the UK.

A crucial asset at their Somerset facility is its Structural Test Laboratory (STL), which is responsible for mechanically testing critical aircraft components to destruction. As part of an ongoing development programme, the client wanted to create a dedicated and permanent hydraulic supply to its expanding fleet of testing equipment.

Rotec Hydraulics Ltd added several significant upgrades to the current system in three stages; install 4 air blast coolers, design and install a custom sub ring main within the new Fatigue Lab and finally to design and install a major upgrade to the existing distribution ring main.

As part of the second and final phases of the project, Rotec designed and built a number of bespoke pipework brackets, stands and manifolds all of which were FEA tested by our in-house design engineers to ensure they exceed the minimum design requirements set by the customer.

More than 21.5 metres of pressure and return pipework was manufactured on site using Parker’s unique High Pressure Flange system making for a very quick and efficient installation. The 80 x 10mm 6k steel pipework is capable of operating at 420 bar maximum working pressure and was connected using Rotec’s in-house designed “X-Blocks” which distributed the flow to numerous outputs.

Rotec’s capabilities are that of significant breadth meaning, unlike many competitors, Rotec is able to design, build, install, commission and maintain systems in-house to a consistently high standard. To find out more, visit our services page.