Rotec Hydraulics launches first-of-its-kind Electric Winch System

Our team at Rotec Hydraulics Ltd, experts in system solution design, have developed a pioneering electric winch system that offers a zero-emission alternative to hydraulic winches. This innovation supports customers in achieving net zero goals with enhanced performance and precision.

“This project is an example of how Rotec Hydraulics is spearheading electrification within the fluid power industry to enable decarbonisation of the hardest-to-abate industry sectors.

“The addition of Parker components, including IQAN technology, has made the challenge of producing the same, if not enhanced, performance compared to the equivalent hydraulic winch system solution possible.”

– Paul Prouse, Managing Director of Rotec Hydraulics Ltd.

Our in-house design team have innovatively designed and developed the first-of-its-kind electric winch system in response to a request from a client. The customer, a national company working within the utilities sector, has ambitious net zero goals and Rotec, as its sole winch design, supply and service provider was keen to support.

Expertise in system solution design

The ambitious R&D project was specifically dedicated to produce an electric winch with the equivalent performance and functionality of the hydraulic winch that the client currently uses on their large fleet of Isuzu D-Max vehicles.

Stepping up the design challenge

Despite other winch providers saying an electric winch system capable of proportional speed control lifting 1.5 tons and dragging 3.6 tonnes and not overheating was impossible, we are pleased to reveal our new offer to the market.

This particular example features two operational modes (lifting and pulling). The proportional speed control allows for safe, controlled ascent and descent of the winch system when lifting.

Operators have reported that the infinite winch speed control using joysticks in cab and/or remote pendant have allowed for more precise and accurate placing of the load than the previous hydraulic winch delivered.

The integrated thermal management of both motor and motor inverter along with natural air cooling of the motor inverter, means that Rotec’s electric winch system has an unlimited run time.

The electric winch system is fully customisable to any future clients looking to change to fully electric winches.

Sustainability

Our electrical winch system reduces CO2 emissions as a result of being powered by a lithium battery, rather than the vehicle’s diesel engine.  The vehicle engine does not need to be turned on in order to operate the winch, unlike its hydraulic counterpart. 

The electric winch’s carbon emissions are minimised with the only emissions being those generated when the vehicle is in motion and it is charging the winch system’s lithium battery.

Not just a supplier of parts

Winner of Manufacturer of the Year 2023 at the Somerset Business Awards, we can provide tailored winch system designs to your vehicle and operational requirements and offer design, manufacture, fitting and on-site servicing and repair service backed with consistent excellent customer service. 

Customers can customise rated line pull, line speed or rope type and capacity to optimise their operations. High quality, robust components mean all Rotec winch systems are suitable for operating in challenging environments.

Our innovative electric winch system has enabled its customer to not only cut emissions but work smarter, more accurately and increase productivity with proportional control capability and/or remote monitoring options.

 

Find out more about Rotec’s winch offer at Winch systems – Rotec Hydraulics Ltd.

Track and Manage Assets Worldwide

Parker Tracking System (PTS) is an innovative component-tagging and asset management solution offered by Rotec Hydraulics.

Record, manage and retrieve critical asset information with PTS.

This innovative system provides fast and accurate product information,
speeding replacement regardless of where or when the original component was created. Because tagged products can be replaced sight unseen, PTS eliminates the need to wait for removal before new parts can be acquired. Reducing transaction time means users can realize significant gains in productivity and equipment uptime.

Maintenance, Repair and Operations (MRO) can be greatly enhanced by customizing PTS and integrating it into existing systems. 

With seamless data integration, Parker enables bi-directional transfer of critical data to maximize asset visibility and performance. For details on supported platforms and protocols, contact a member of our team.

PTS works seamlessly around the world. Whether you sell, service or operate products and equipment in one city, one state or worldwide, PTS can be tailored to your needs. Equipment built in one country that is sold and serviced in another can use PTS to deliver accurate product details wherever and whenever they are needed.To support our global footprint, PTS offers translation in multiple languages.

For more information, download the PTS brochure here and get in touch with our Sales Team on 01823 348900 or email sales@rotec.net.

100% Achilles audit _Rotec Hydraulics Ltd

Kitting Services and Hose Assemblies tailored to your needs

Looking to reduce inefficiency and increase your team’s capacity?

Eliminate non-value added activities and increase your productivity with Rotec’s Bespoke Kitting Service.

 

All components and sub-assemblies are labeled and packaged neatly together with a list detailing parts and quantities for your convenience. 

Whether you need basic to the most complex kits with multiple assemblies, Rotec Hydraulics delivers kit solutions to help you meet performance goals.

Benefits

  • Simplifies Inventory Management: Reduces volume of individual components to stock manage.
  • Increases Productivity: Your team no longer need to pick parts from different areas. Instead they have a kit ready to go so they can get on with the job in hand.
  • Reduces Manufacturing Time: Kits are tailored to your needs and can include pre-assembled items.

Getting Started

  • Establish a Bill of Materials: Identify items and quantities.
  • Identify Packaging Requirements: Define custom tagging/labelling.
  • Specify sub-assemblies: Decide if any pre-assembled items are required.
  • Request Custom Quote: Email sales@rotec.net or phone 01823 348900 to speak to a member of our team. 
It’s that simple!  Get started by clicking the button below and our Sales Team will be in touch to discuss your requirements.
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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.

A basic guide to hydraulic oil

Hydraulic oil is a non-compressible fluid that is used to transfer power within hydraulic machinery and equipment, and lubricates system components. It is crucially important to regularly check and maintain a system’s hydraulic fluid.

Hydraulic oil can be synthetic or mineral based. Other chemical additives are often added to hydraulic fluid to maintain or improve performance of the oil and the equipment within the hydraulic system. The additives can help to prevent corrosion, rusting and water contamination. It is critical the appropriate oil is chosen for each system. Using the incorrect oil can lead to performance issues and potentially system and component damage.

Additives may include anti-freeze for oils that are been used in harsh, cold environments. In the event of high temperatures, which in turn would lower the oil’s viscosity and increase the risk of leakages, additives may be added to maintain a suitable viscosity for the system being used.

If hydraulic fluid is being used in a high pressure condition, heavy-duty oil is necessary. Heavy-duty hydraulic oil often contains additives that prevent wear.

Biodegradable and environmentally-friendly oils are excellent for those working in sectors that may pose a potential risk of oil spills or leak, and thus environmental contamination. The oils, which are made of rapeseed and other vegetable oils, are also great for businesses with sustainability awareness and targets.

Hydraulic oil life

It’s important to maintain healthy hydraulic systems and components, a crucial part of this is looking after your hydraulic oil.

Modern hydraulic systems are typically smaller and use less oil during operation. Pumps can also produce a lot more output, subsequently producing higher pressures. Less oil means higher fluid temperatures – which in turn, increases oxidation and thermal stress on the additives on the oil. 

Several factors can influence hydraulic oil longevity including:

  • Oil quality
  • Working conditions
  • Oil temperature
  • Oxidation
  • Contamination.

Within the right environment and with the correct maintenance, a high quality oil may last longer than six months. 

For technical support and more information about choosing and maintaining hydraulic oil for your systems, contact Rotec via sales@rotec.net or phone 01823 348900. 

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A guide to hydraulic motors

Axial piston, radial piston, hydraulic gear or hydraulic vane – there are numerous types of hydraulic motors.

When operated, a hydraulic motor uses hydraulic pressure to rotate. Power fluid enters the hydraulic motor, turning the shaft. The volume of oil supplied by the pump determines the velocity of the motor. Thus, the torque generated is dependent on the amount of supplied pressure.

Axial piston motors

Axial piston motors use a bent axis design or a swash plate principle. The fixed displacement type works as a hydraulic motor and can be used in open and closed circuits. In contrast to this, the variable displacement type operates like a hydraulic pump.

In the bent axis design, pistons move to and fro within the cylinder block bores. This movement is converted into rotary movement via the piston ball joint at the driving flange. In the swash plate design, pistons move to and fro in the cylinder block. Subsequently it revolves and turns the drive shaft via the connected cotter pin.

Radial piston motors

Highly efficient and usually long-lasting, radial piston motors provide excellent low speed operation with high efficiency and generate high torque at relatively low shaft speeds. Referred to as LSHT – Low Speed High Torque motors, the low output speed means in some cases a gearbox is not required.

Radial piston motors are commonly found in: excavators, cranes, ground drilling equipment, winch drives, concrete mixers, trawlers and plastic injection moulding machines. Generally, there are two basic types of radial piston motors – crankshaft radial piston motor and multilobe cam ring design. Other types of radial piston motors include compact radial piston motors, dual displacement radial piston motors and fixed displacement radial piston motors.

Hydraulic gear motors

A hydraulic gear motor consists of two gears: the driven gear (attached to the output shaft by way of a key) and the idler gear. High pressure oil is ported into one side of the gears, where it flows around the periphery of the gears, between the gear tips and the wall housing, to the outlet port. The gears then mesh, not allowing the oil from the outlet side to flow back to the inlet side.

For lubrication, the gear motor uses a small amount of oil from the pressurized side of the gears, bleeds this through the (typically) hydrodynamic bearings, and vents the same oil either to the low pressure side of the gears, or through a dedicated drain port on the motor housing.

One very important gear motor feature is that catastrophic breakdown is a lot less common than in most other types of hydraulic motors. This is because the gears gradually wear down the housing and/or main bushings, gradually reducing the volumetric efficiency of the motor. The gear motor can degrade to the point of near uselessness. This often happens long before wear causes the unit to seize or break down.

Hydraulic vane motors

Hydraulic vane motors are used in both industrial and mobile applications. For example, screw-drive, injection moulding and agricultural machinery. These motors tend to have less internal leaking than a gear motor. And subsequently, they are better to use in applications requiring lower speeds.

Hydraulic vane motors feature reduced noise level, low flow pulsation, high torque at low speeds and a simple design. Moreover they are easy to service and suitable for vertical installation. To function correctly, the rotor vanes must be pressed against the inside of the motor housing. This can be done through spiral or leaf springs, but rods are also suitable.

A vane motor typically features a displacement volume between 9 cc/rev to 214 cc/rev and a maximum 230 bar pressure. The speeds range from 100 to 2,500 rpm. Maximum torque of up to 650 Nm.

For technical support and more information on hydraulic motors, contact the Rotec sales team via sales@rotec.net or phone 01823 348900.

To browse our hydraulic motor products, visit https://rotec-catalogue.co.uk/hydraulics/components.