Remote system fitted to quarry conveyor improves safety and operational control

100% Achilles audit _Rotec Hydraulics Ltd

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.

100% Achilles audit _Rotec Hydraulics Ltd

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.

Rotec deliver custom upgrade and HPU builds for leading manufacturer

Recently designed and manufactured, engineers at Rotec Hydraulics Ltd have completed a bespoke project for a market-leading manufacturer.

The British-based company specialise in the manufacture of electronic valve actuators for large fluid flow applications, for example within the oil and gas, water and power industries. The actuators produced are a considerable size and as such, part of the development process includes dynamic load testing. The actuators connect to a test cylinder via a screw thread; as the actuators move the screw thread up and down, this in turn pushes and pulls a hydraulic cylinder.

 Full of hydraulic fluid, the operators were manually operating needle valves to restrict the flow of the hydraulic fluid within the cylinders in order to vary the amount of load on the actuator. Thus, Rotec design engineers developed two key upgrades to this current setup which were:

  • Electrify the load control valves so they can be operated by a computer.
  • Create a power pack which can induce a given pressure inside the test cylinder bores.

 The newly custom-designed system reuses the current cylinders that vary in size from 63mm in diameter to 203mm. To accommodate for this, different sized stands with varying tank sizes have been manufactured to accommodate the extra capacity whilst the control components remain the same. The stands consist of:

  • A custom powder coated steel frame.
  • An aluminium reservoir.
  • Dual electronic proportional pressure relief valves.
  • Dual manual needle valves.
  • Dual ball valves.
  • Quick connect ports for the power pack to connect to.
  • Output ports which connect to the test cylinder.

In addition to this, Rotec developed and built three identical standalone hydraulic power unit (HPU) systems which can create steady state pressures inside the test cylinders bores to eradicate erroneous pressure lag errors. Features include:

  • Powder coated mild steel tank construction.
  • 3 phase motor coupled to a gear pump.
  • Air blast oil cooler.
  • Direction control valve.
  • Dual proportional relief valve.
  • Electronic control box.
  • Stainless steel tool tray.
  • Whole unit is mounted on castors for easy manoeuvrability.

For more information on Rotec’s capabilities, including project case studies, visit www.rotec.net.

Stroud Engineers Deliver Major Refurbishment Projects at BMW

Rotec engineers carried out a major refurbishment of the Feed Line and Press at a BMW plant in Gloucestershire.

Over 160 hydraulic hoses on the Feed Line, and 66 hoses on the Major Press were removed and new hoses made and fitted.

This was a challenging job due to the complexity of the machinery and included hoses on the Feed Line HPU (hydraulic power unit), Press and Overload/Protection/Lubrication HPUs. Feed Line Pneumatic cylinders, valves and tubings were also supplied and fitted, in addtion to a total of 48 existing hydraulic cylinders on the Feed Line removed and new cylinders fitted.

Further work taken on the Feed Line, Press and Overload/Protection/Lubrication HPUs included:

  • Draining of the working fluid and cleaning of the reservoir.
  • Replacement of pressure and return hydraulic filters, pressure and return.
  • Replacement of pressure and return hydraulic filters, pressure and return.
  • Resealing of duplex filter block.
  • Removal of existing and refitting of new motor pump sets.
  • Thorough cleaning and inspection.
  • Removal of existing and refitting of new air blast coolers.

All refurbishment works were carried out on time, in budget and to the client’s expectations and standards.

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