Hydraulics - Rotec Hydraulics Ltd

Managing Hydraulic Systems in High-Temperature Environments

High temperatures pose a significant threat to the performance and longevity of hydraulic systems. Elevated heat can lead to a rapid decline in fluid quality, premature component wear, and potential system failure. We’ve summarised some proactive maintenance measures you can take to mitigate these risks and maintain operational reliability.

Fluid Temperature Monitoring

Regularly monitoring hydraulic fluid temperature is critical. The ideal operating range for most systems is 40°C to 60°C (104°F to 140°F). Temperatures exceeding this range accelerate fluid degradation. Systems should be equipped with a reliable temperature gauge to provide accurate and continuous readings. A significant increase in temperature from a known baseline indicates a potential issue requiring immediate attention.

Hydraulic Fluid Selection and Management

The viscosity of hydraulic fluid is directly affected by temperature. As the temperature rises, viscosity decreases, reducing the fluid’s ability to lubricate components effectively.

Adherence to specifications: Always use the hydraulic fluid recommended by the manufacturer. This fluid is designed to maintain optimal performance within the specified operating parameters.
Viscosity Index: In consistently hot environments, a fluid with a higher viscosity index (VI) may be considered, but only after consultation with a hydraulics expert or the equipment manufacturer. A higher VI indicates less change in viscosity with temperature fluctuations.
Fluid levels: Maintain correct fluid levels to prevent cavitation, which occurs when air bubbles form and collapse, causing damage to pumps and other components.

Cooling System Maintenance

The hydraulic cooler is vital for dissipating heat. Its efficiency is paramount in high-temperature conditions.

Regular cleaning: The cooler’s fins must be kept free of debris, such as dust, dirt, and leaves, which can restrict airflow. Use compressed air or a soft brush to clean the surface regularly.
Inspection: Inspect the cooler for any damage, such as bent fins, that could impede heat exchange.
Fan operation: For forced-air coolers, verify that the fan is operating correctly and is free from any obstructions or electrical faults.

Operational Practices

Operational practices can significantly influence a system’s thermal load.

Duty cycles: Avoid continuous, high-load operation during the hottest periods of the day. Scheduling demanding tasks for cooler hours can reduce thermal stress on the system.
Load management: Where possible, reduce the load on the equipment to decrease the amount of heat generated.

Component Integrity Checks

High temperatures can degrade seals and hoses, leading to leaks and component failure.

Leak inspection: Regularly inspect all hoses, seals, and connections for signs of leaks. Heat can cause materials to harden and crack, compromising their integrity.
Physical inspection: Check hoses and seals for signs of blistering, cracking, or other physical deterioration.
Connection integrity: Ensure all connections are properly tightened to prevent leaks caused by vibration and thermal expansion.

By implementing these preventative maintenance measures, system operators can ensure the long-term health and efficiency of their hydraulic equipment, even under the stress of high-temperature conditions.

How Rotec Hydraulics Builds Smarter Systems with Parker IQAN Software

100% Achilles audit _Rotec Hydraulics Ltd

As a certified Parker distributor, Rotec Hydraulics is at the forefront of designing and building custom hydraulic systems that are not just powerful, but also smart. By integrating Parker’s IQAN electronic control system, we create solutions that enhance safety, boost efficiency, and provide unprecedented control over your equipment.

What is Parker IQAN and What are the Benefits?

Parker IQAN is a state-of-the-art electronic control system specifically designed for mobile hydraulic applications. It’s an integrated ecosystem of controllers, displays, joysticks, and sensors, all managed by a powerful and user-friendly software suite.

The key benefit of IQAN is its ability to replace complex mechanical and electromechanical systems with a streamlined, totally electronic approach.

Rotec has successfully designed, built, programmed and installed a variety of custom IQAN-enhanced systems. Clients have reported benefits including:

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Enhanced Safety

IQAN controllers enable critical safety features like dual-channel fail-safe circuits and emergency stops which can be operated remotely. This enhances safety – keeping operators out of harm’s way, especially in hazardous environments such as quarries or construction sites.

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Precision & Control

The software allows for precise, proportional control of hydraulic functions. Instead of simple on/off levers, operators can achieve infinite speed control and finely tune movements with joysticks and other input devices. This leads to more accurate and efficient operations.

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Monitoring & Diagnostics

IQAN systems provide real-time monitoring and advanced diagnostics. The software logs events, and can alert operators to potential issues before they cause a breakdown. This proactive approach to maintenance dramatically reduces downtime and lowers repair costs.

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Remote Accessibility

Rotec can build systems that allow for remote monitoring, diagnostics, and even software updates. This means operators can access the system’s data from a laptop or smartphone, diagnose a problem, and potentially resolve it without needing to be on-site.

Customisation

IQAN software is flexible and user-programmable. Rotec Hydraulics’ in-house design team can customize the system to your specific needs, building in tailored functions, adjusting parameters, and creating a user interface on the display that is intuitive for your operators.

Why Choose Rotec?

By choosing Rotec Hydraulics, you’re not just getting a hydraulic system; you’re getting a complete, integrated solution. Our expertise in both hydraulic and electrical mechanical systems, combined with the power of Parker IQAN, allows us to:

Design and Build: Create bespoke hydraulic power units and control systems from the ground up, tailored to your application.
Install and Integrate: Seamlessly integrate new electronic controls with your existing machinery, replacing outdated components with modern, smart technology.
Provide Ongoing Support: Offer remote diagnostics, software updates, and expert maintenance to ensure your system continues to run at peak performance.

Examples of Rotec-designed IQAN systems include a remote control system built for a quarry, which enabled operators to control heavy machinery from a safe distance, drastically improving safety and efficiency. Another project involved the development of a pioneering electric winch system, where Parker IQAN technology was instrumental in achieving precise proportional speed control – a function previously thought impossible for an electric system.

For more information, request a discussion with a member of our Sales Team via sales@rotec.net.

Streamline Your Manufacturing with Rotec’s OEM Kitting Service

In today’s competitive manufacturing landscape, efficiency and cost-effectiveness are paramount. Original Equipment Manufacturers (OEMs) are constantly seeking ways to optimise their operations, reduce lead times, and improve productivity. One solution is Rotec’s bespoke kitting service -streamlining your assembly lines and reducing lead times, it helps improve your time-to-market and gain a competitive advantage.

What is an OEM Kitting Service?

OEM kitting involves assembling all the necessary components for a specific product or sub-assembly into a single, convenient kit. This can include everything from hose assemblies, adaptors, seals, and o-rings, to pumps, valves, oils, and filters – essentially, any component your product requires. Rotec Hydraulics works closely with OEMs to tailor these kits to their exact specifications, ensuring every part is present and accounted for.

How Rotec’s Kitting Service Benefits Your Business:

Our OEM kitting service is designed to be a complete solution, offering a range of value-added services, including:

Customized Kitting: We work with you to understand your specific needs and create kits that perfectly match your requirements. No more searching for individual parts – everything you need arrives in one package.
Comprehensive Component Sourcing: We handle the procurement of all necessary components, saving you time and effort. Our extensive network of suppliers ensures access to high-quality parts at competitive prices.
Value-Added Services: We can include testing, labeling, bagging, and other services to further streamline your production process. Just let us know your requirements, and we’ll take care of the rest.
UK and European Coverage: Rotec Hydraulics serves clients across the UK and mainland Europe, ensuring consistent supply regardless of your location.
Reduced Costs and Improved Efficiency: Kitting can significantly reduce your purchasing activity, speed up goods receipt, and improve productivity. By consolidating your supply chain, you can also reduce the number of suppliers you need to manage, leading to fewer invoices and simplified administration.

“Rotec’s kitting service has streamlined our assembly lines, reducing assembly time and boosting productivity.”

Purchasing Manager

Marine industry

Partner with Rotec Hydraulics:

If you’re looking for a way to optimise your manufacturing processes and improve your bottom line, consider partnering with Rotec Hydraulics for your OEM kitting needs.

Contact us today to discuss your requirements and discover how we can help you achieve your goals. Let us help you build a more efficient and competitive business.

Get in touch

Two HPUs and Ten Jacking Cylinders Manufactured for New Client

Earlier this month, Rotec Hydraulics completed a large project for a new customer who specialises in all aspects of confined space working from sewer rehabilitation, timber headings, tunnelling, grouting, all types of shaft sinking and associated clean and waste water works.

With a wealth of experience constructing shafts up to 30 metres in diameter and to depths of 35 metres, the specialist construction company sink shafts using various techniques – including hydraulically jacking segmental shafts vertically.

Rotec were asked to design, build and deliver ten hydraulic cylinders and two hydraulic power units (HPUs) capable of powering 40 tonne hydraulic jacks with up to 210 bar pressure for a significant shaft sinking project.

The HPUs operate ten hydraulic jacking cylinders using ten off detented levels and a single sprung loaded dead man’s lever. The jacking cylinders have a 160 bore, 110 rod, 1200 stroke and are mounted in frames which push down concrete segments to line holes. Each cylinder can provide up to 40 tonne force with 210 bar pressure which can be controlled by an adjustable knob on the HPU.

To speed up the extension and retraction of the cylinders, the HPUs have been designed with a two-stage pump which produces a faster flow when less hydraulic pressure is required. The pump is powered by a 7.5 kW 3-phase electric motor which is controlled by electrics mounted in an enclosure on each HPU. This allows the pump to be started and stopped easily, as well as providing essential emergency stop buttons.

Both HPUs have a 500 litre tank with pressure and return filters, in addition to a fitted level/temperature gauge. Connections from the HPUs to the cylinders are via protected hoses with quick release connectors.

To increase safety and reduce risk of harm to the operator, the hydraulic hoses on both the HPU and those to the hydraulic cylinders have been fitted with hose burst protection and whip checks where necessary.

Remote system fitted to quarry conveyor improves safety and operational control

Rotec Hydraulics have designed and installed a remote system, improving safety and operational control for our client at a significant limestone extraction quarry located within the South West of England.

Our customer utilises two tracked crawler vehicles to lift and manoeuvre a length of conveyor into position at the quarry. Previously, the vehicles had to be driven locally by personnel on the machine. To increase safety there was a request to design a system which would allow the machines to be operated remotely, keeping persons away from potential falling objects on the conveyor.

The remote system has additional benefits – including improving efficiency and the communication between machine operators because they can now stand next to each other and tandem lift with greater synchronisation. Previously they would be at opposite ends of the conveyor and this would require multiple banks-man and hand signals.

Rotec’s technical team and engineering team designed and fitted a new control system based around a Parker IQAN mobile specific safety controller which uses CAN Open protocol to safely communicate with a radio remote system.

Existing manually operated valves were exchanged for electronic proportional control, allowing the operator to drive all the hydraulic functions remotely that were previously only available using hydraulic levers locally on the vehicle.

Backup electronic joysticks have been installed locally on the vehicle if the remote control was ever to become damaged during use, eliminating the risk of the vehicle becoming stranded in this rare scenario.

Our customer requested we fitted their own specific blue warning lamps and white noise sounders, all of which are driven directly from the new safety controller.

The existing emergency stop system was removed and replaced with an updated dual channel fail safe circuit featuring safety relays, bringing the equipment up to modern safety standards. Emergency stops include one located on the remote control allowing the operator to stop functions quickly and safely from a distance.

The newly installed Rotec control system integrates with the existing engine controller to allow warning messages to be displayed on the screen located on the remote, providing the operator with ultimate feedback if any engine faults develop during use.

Rotec also installed a Bluetooth modem allowing the customer to make certain parameter changes to the control system using a free app that is available to download.

The app enables any user to view logs, check the health of the system and monitor various sensors all wirelessly from a smartphone or tablet. Additional features include the ability to connect the machine to the internet so Rotec staff can remotely assist, diagnose and install software updates if required. Password protection has been employed to prevent abuse of the system by anyone except personnel issued with the login credentials.

To integrate with the client’s corporate branding, we customised the remote control with the client’s logo. Customisations such as switch positions and labeling were also discussed and agreed with the customer before build to ensure we delivered the best customer service and client satisfaction.

Rotec Hydraulics receives ‘Lifetime Supporter Award’ from the British Fluid Power Association (BFPA)

Last month, Rotec Hydraulics proudly welcomed the British Fluid Power Association (BFPA) to their headquarters in Taunton, Somerset to be presented with a BFPA award.

The esteemed Lifetime Supporter Award by the BFPA recognises our commitment, dedication and support to the British fluid power industry. The award also celebrates Rotec’s special and longstanding relationship with the BFPA.

Rotec Hydraulics was a founding member and key player in the development of the BFPA, which is now in its 65th year. As a founding member, we played a pivitol role in setting up the UK’s only trade body for the Hydraulic and Pneumatic industries.

Rotec’s Managing Director, Paul Prouse, comments,

“Rotec Hydraulics was one of the founding members of the BFPA 65 years ago, and it is a privilege to continue our involvement. The BFPA plays a crucial role within the industry for standards, legislation and training and we are proud to continue to support and work closely with the BFPA.”

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