Hydraulics - Rotec Hydraulics Ltd

Rotec Completes Critical Refurbishment of Canal Lock Lift Bridge System

100% Achilles audit _Rotec Hydraulics Ltd

Rotec Hydraulics, a leading provider of hydraulic engineering solutions, have completed a recent project involving the removal, overhaul, and refitting of two critical hydraulic cylinders for a Canal Lock Lift Bridge.

The project, which also included the fabrication of a new bespoke clevis frame assembly and the replacement of hydraulic hoses, was executed to ensure the continued safe and reliable operation of the waterway infrastructure.

Due to the age and wear on the existing components, the overhaul was critical. Rotec’s work covered the entire lifecycle of the component replacement, from initial isolation to final commissioning:

Cylinder Removal and Preparation: Rotec engineers worked alongside the customer’s team to safely isolate and remove both hydraulic cylinders from the bridge structure, before transporting them to the Rotec workshop for overhaul.
Comprehensive Cylinder Overhaul: Involved stripping the cylinders, removing seized bolts and eyes, manufacturing new 4-inch rods, and performing repairs and refurbishment on the glands and pistons. The cylinder tubes were polished, and new seal kits were supplied and installed before the cylinders were re-assembled and tested.
Reinstallation and Commissioning: Following overhaul, the cylinders were delivered back to the site. Rotec provided installation assistance, topped up the system with new hydraulic oil, and oversaw the final onsite testing to ensure safe and optimal performance.

The project also encompassed the fabrication of a replacement frame for the cylinder base end clevis.

Clevis Frame Assembly: Rotec reverse-engineered measurements from the existing components to design and fabricate a new clevis frame assembly. The new frame was upgraded with larger side plates for increased durability. The fabrication underwent die-penetrant weld testing to confirm structural soundness.
New Components: The project included the machining and supply of a replacement clevis pin and four new pin locating plates.
Hydraulic Hose Assemblies: Rotec supplied and installed four new replacement hydraulic hose assemblies with stainless steel over braid, all of which were pressure tested prior to commissioning.

“Successfully refurbishing these critical cylinders and simultaneously fabricating a key structural component, all while minimising disruption, underscores our commitment to maintaining essential infrastructure,” commented Dale Lockart, Branch Manager of Rotec’s Stroud Service Centre.

The successful completion of the cylinder overhaul and clevis frame replacement ensures the continued operational efficiency and safety of the Canal Lock Lift Bridge for many years to come.

For more information on the services offered by Rotec, contact sales@rotec.net or phone 01823 348900.

Rotec Hydraulics Powers F1 Performance with Remote-Monitored HPU & Flushing Rig

Rotec Hydraulics, a leader in high-performance fluid power solutions, has engineered a custom Hydraulic Power Unit (HPU) and Flushing Rig for a global F1 team, tackling the challenge of delivering safe, precise, and reliable pressure while ensuring optimal system longevity.

Race car hydraulic systems demand meticulous maintenance, including regular flushing to prevent contamination—the primary cause of system failure. Traditional, bulky on-site equipment often leads to logistical issues and unwanted downtime. Rotec’s innovative solution merges two critical functions into one compact, portable unit.

The custom 3 kW HPU is designed to deliver 200 Bar of pressure at 8 Liters per Minute (LPM) to power race car hydraulic components. More crucially, it features an integrated flushing rig and particle counter, enabling technicians to maintain pristine oil cleanliness.

A key differentiator is the integration of remote diagnostics via Parker IQAN technology. The HPU utilises Bluetooth connectivity to allow remote monitoring and control via a tablet or smartphone. This provides instant, detailed data on sensor and output states, including pressure, temperature, flow, and contamination levels.

Jesse Cherry, Business Development Manager at Rotec Hydraulics commented,

“This project showcases Rotec’s ability to deliver bespoke, high-performance hydraulic solutions that directly address challenges. We understood the critical need for a reliable, safe, and mobile solution. The integration of remote diagnostics streamlines operations and provides a great benefit to our client.”

The dual-functionality, combined with remote diagnostic capabilities, transforms maintenance from reactive repairs to proactive system health management. This compact, maneuverable rig minimizes maintenance time, boosts operational efficiency, and significantly reduces the risk of critical hydraulic failures—a crucial competitive edge in the high-stakes world of Formula 1.

Discover Rotec’s full capabilities via their website www.rotec.net or call 01823 348900 to discuss your requirements.

Servicing Hydraulic Systems for Harbour Authority

At Rotec Hydraulics, we believe that a well-maintained hydraulic system is the backbone of efficient and reliable operations. We recently carried out essential hydraulic power unit (HPU) servicing for a returning customer – a major harbour authority in Devon.

Our experienced engineers carried out a thorough service of the client’s HPU, including:

HPU Draining & Oil Replacement: We began by draining the old hydraulic oil from the HPU, preparing the system for a fresh start.
Critical Hose Replacements: The project required the replacement of two steering system “severe rated” hydraulic hose assemblies. Our engineers manufactured new hoses, making them 150mm longer to allow for better routing around a tie-rod. This small modification significantly reduces wear and tear and extends the life of the hoses. We also identified and replaced two additional hose assemblies with damaged outer sleeving, preventing potential future failures.
Component Inspection & Servicing: We removed and inspected the slow stow adjuster and its associated solenoid. This step involved servicing, cleaning, and replacing seals as needed, ensuring these components operate flawlessly.
System Flushing & Filtration: To guarantee a clean system, we installed a temporary hydraulic filter in the Man Overboard (MOB) system. We then refilled the tank with BIO ISO-32 oil and ran the system through, directing the flow of oil through the pressure filter to effectively flush out any contaminants.
Final Commissioning: After the flushing process, we reinstated the system, carefully bled the lines, and performed a comprehensive commissioning to ensure everything was functioning correctly. We also performed fault-finding on the MOB system, addressing any issues proactively.
Site Clean-up: We believe a job isn’t complete until the site is left clean and tidy, a final touch that underscores our professionalism and respect for our client’s workspace.

If you are looking to secure the longevity and reliability of your hydraulic systems, a proactive maintenance plan is a wise investment. Contact Rotec Hydraulics today to learn how our team can help you safeguard your operations via sales@rotec.net or phone 01823 348900.

Preventative Maintenance for Hydraulic Pumps to Boost Efficiency and Reduce Downtime

At Rotec Hydraulics, a Parker Certified Hydraulic Technology Centre with over 45 years of experience, we advocate businesses to adopt a proactive approach to hydraulic pump maintenance.

Preventative care is far more cost-effective than reactive repairs, which is why we offer flexible preventative maintenance service contracts to help clients avoid costly and unexpected system failures.

Proactive Hydraulic Pump Maintenance

Hydraulic pumps are at the heart of hydraulic systems. However, without regular maintenance, their performance can quickly degrade, leading to inefficiency, increased energy consumption, and catastrophic failures.

Routine maintenance and inspection are crucial because:

They prevent expensive breakdowns: A small, easily fixed issue, like a worn seal or contaminated fluid, can escalate into a complete pump failure, requiring a full and costly replacement.
They extend equipment life: Regular servicing and timely replacement of components—such as seals, bearings, and filters—significantly extend the operational life of the pump.
They improve efficiency: Clean, well-maintained pumps operate at peak performance, reducing energy waste and ensuring the system performs as designed.

A thorough strip-down and inspection is recommended every 2,000 to 4,000 operating hours or as indicated by the manufacturer. This may also be reduced if operating in a particularly harsh environment. Rotec’s in-depth service allows technicians to identify internal wear and tear that isn’t visible during routine checks.

The Rotec Hydraulics Advantage

Choosing the right service provider is paramount. Rotec Hydraulics is uniquely positioned to offer superior hydraulic maintenance services.

Parker Certified Hydraulic Technology Centre: As the only accredited Parker Hydraulic Technology Centre in the South of the UK, Rotec guarantees services performed to the highest industry standards.
Decades of Expertise: With over 45 years in the industry, Rotec has a deep, hands-on understanding of hydraulic systems across various sectors, from industrial and marine to defense and agriculture. This extensive experience ensures accurate diagnostics and effective, long-lasting repairs.
Preventative Maintenance Service Contracts: Rotec offers customised service contracts tailored to a business’s specific needs. These contracts schedule regular inspections and maintenance, taking the guesswork out of pump care and ensuring a system’s health is always a priority. This approach not only minimizes downtime but also provides a detailed service history for audit purposes and offers emergency support.

“We believe in helping our clients shift from a reactive to a proactive maintenance strategy,” says Mark Conniff, Operations Manager. “Our goal is to ensure their hydraulic systems are reliable, safe, and efficient. With our Parker certification and extensive experience, we take pride in our level of service and expertise.”

For more information on our preventative maintenance services or to schedule a consultation, please phone 01823 348900 or email sales@rotec.net.

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

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.

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