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.

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. 

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.

Rotec provides IoT technology for smart monitoring

Internet of Things (IoT) technology enables engineers to remotely control and monitor various performance and safety parameters using strategically placed, wireless sensors to provide data and control systems over the internet.

IoT technology can lead to a reduction in downtime, better response rates and speed of intervention for predictive maintenance.

Everyday examples of IoT include smart home security systems or wearable health monitors. In terms of engineering, the potential for IoT is staggering, from autonomous agricultural equipment to advanced monitoring systems allowing machinery to be monitored from any location worldwide.

With more than 7 billion connected IoT devices today, experts are expecting this number to grow to 10 billion by 2020 and 22 billion by 2025.

Rotec has invested in IoT devices to offer this forethinking technology to our new and existing customers, as part of the business’s strategy to maximise the use of the latest technology, data analysis and to find environmentally sustainable solutions for our customers. We are now the only company South of England to be offering a range of Parker IoT products suited to all sector markets that rely on hydraulic, pneumatic and electrical mechanical engineering solutions. 

This data centric and digital approach enhances both our own and our clients’ understanding of what really ‘works’ when designing hydraulics, pneumatics and electrical mechanical systems. It complements the other services delivered by of our brand such as bespoke design, custom builds, maintenance, repair and overhaul activities.

IoT can be applied to all sectors. Examples include IOS; an innovative solution to measuring the quality of hydraulic oils and hydrocarbon fuels. Lightweight, robust and portable, IOS features a laser detection particle counter, battery and pump plus memory with web page generator for data download onto any PC or laptop – enabling clients to sample oil on-site and gather results within 2minutes. The IOS’s ability to sample directly from a hydraulic reservoir, barrel, vehicle fuel tank or from a high pressure online hydraulic system with the addition of a pressure reducing adaptor makes it undoubtedly the most adaptable contamination service tool available today. 

Another Parker IoT product range Rotec are proud to offer is an extension to the IQAN mobile controller family of hardware; products we have very extensive experience and knowledge of . This product range permits clients to quickly write applications for the desired functionality of their machine, reducing programming time and expense for machine control systems.

We are currently researching and designing a custom-made, cutting-edge hydraulic system, with IoT for remote monitoring embedded into the design, for a prominent name within the UK marine industry. Using Rotec designed test case fitted with Parker IQAN and GPS hardware, our client will have the technology to remotely dial in to monitor the hydraulic system sensors. This ability to proactively monitor remotely has numerous benefits, including reducing severity of damages caused by contamination and temperature, as well as reducing downtime for non-remote monitoring activities.

To discuss your requirements, and speak to a member of our team about IoT, please contact sales@rotec.net or call 01823 348900.

Custom made hydraulic winch system for the utilities sector

Rotec Hydraulics Ltd has recently completed works on a custom made hydraulic winch system for the utilities market.

Fitted to a fleet of National Grid vehicles, these bespoke winches have been designed, built, installed and tested by our in-house team of engineers and include a hydraulic system, electronic control system and mechanical components.

The Capstan winch is specifically designed for fast line speeds and has a 350Kg working load limit with a remote electrical foot pedal operation

Safety features include an integral fail safe static brake and integral dynamic braking.

The Capstan winch drum is made of stainless steel and the winch is deployed on a sliding system to allow the operator to move it from stored position to operational position easily.

National Grid is one of the world’s largest publicly listed utilities focused on transmission and distribution of electricity and gas. They play a vital role in connecting millions of people to the energy they use safely, reliably and efficiently. Rotec has worked with National Grid for several years and are proud of the strong, effective relationship they share.

At Rotec the team work on many different projects.  Much of the work undertaken requires the integration of knowledge and skills from across the Rotec team, to deliver all of the elements that make up a client brief. For more information on the services we offer, please click here.