How Rotec Hydraulics Builds Smarter Systems with Parker IQAN Software

100% Achilles audit _Rotec Hydraulics Ltd
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:

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.

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.

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.

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.

l

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.

Modernising Ramp Actuators

Mitigating obsolescence and ensuring long-term operational efficiency. 

100% Achilles audit _Rotec Hydraulics Ltd

The Challenge: Aging, proprietary ramp actuators (50+ years old) posed maintenance and obsolescence risks, with strict dimensional constraints for replacement.

The Solution: A bespoke engineering solution, developed in collaboration with Landau UK Limited, which delivers a high-performance, modernised replacement using readily available components – reducing obsolescence risks, and extending the serviceable lifespan of the unit.

Key Design Requirements: The new jack was engineered to meet the following critical performance and operational specifications:

  • High Force Capacity (Max pull force: 61,000 kg, max push force: 81,300 kg)
  • Compact Dimensions
  • Fluid Compatibility
  • Weight Optimisation and Manual Handling (Weight reduced from previous jack)
  • Self-Contained System (Integrated design for autonomous operation)
  • Single control interface for intuitive control
  • Manual Backup
  • Over-Pressurization Protection
  • Robust exterior for handling resilience
  • Environmental durability (temp range from -30°C to 48°C, direct saltwater environment)

Manufacturing and Component Strategy: Modern CNC machining techniques employed for manufacturing. Non-machined components, such as o-rings, rod seals, bearings, and fixings, were selected as commercially available products to ensure long-term accessibility.

Testing and Validation: Rigorous factory acceptance testing, utilising a custom 160+ tonne capacity test frame, validated performance under maximum loads.

Delivery and Packaging: Units packaged to stringent Level N Defstan requirements for secure storage and transport.

Outcome: Six units delivered ahead of schedule and fully compliant.

The modernisation provides a sustainable, maintainable solution, mitigating obsolescence and ensuring long-term operational efficiency.

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

Motor Overhaul for Cruise Ship

Rotec’s Electrical Mechanical Services division completed the overhaul of 21 ship’s motors last month for a leading leisure industry company.

The cruise ship, who carries thousands of passengers each year, voyages throughout the Baltic, Norwegian Fjords, and the Mediterranean. In regular use, our engineers had a strict time limit of 14 days to remove, overhaul and reinstate all 21 motors whilst the ship was in dry dock.

The scope of works included:

Removal and inspection

  • Safe and efficient electrical and mechanical disconnection of all 21 motors, including the port and starboard anchor winch motors.
  • Thorough inspection of all plate detail and insulation valves.

Overhaul

  • Full steam cleaning of the motors and re-varnishing as required.
  • Baking of the motors in a temperature-controlled oven to ensure proper curing of the varnish and to remove any residual moisture.
  • New bearings fitted where required.
  • Repair of worn end-shields by sleeving and machining back to tolerance.
  • Replacement of brake pad discs with excessive wear.
  • Insulation tests conducted at 500 volts to ensure electrical safety and integrity.
  • Dynamic balancing carried out to avoid unnecessary vibrations, reduce noise, prevent mechanical failure, and improve balance and efficiency.
  • Inspection of all electrical cables for damage.

Reinstallation

  • Safe and efficient reinstallation of all 21 motors back onto the ship.
  • Careful reconnection of all electrical and mechanical components.

Report

  • A detailed report, with images of all motors, was completed and a copy sent to the client upon completion.

All work was completed within the 14 day schedule deadline.

The completed overhaul will significantly improve the reliability and lifespan of the ship’s motors, reducing the risk of unexpected breakdowns and ensuring continued safe and efficient operation.

If you would like more information on Rotec’s Electrical Mechanical capabilities, contact sales@rotec.net or call 01823 348900.

Boost Efficiency and Safety: Rotec Hydraulics is Your Parker Approved Accumulator Service Centre

Accumulators play a vital role in all industries, ensuring smooth and reliable hydraulic system performance. However, maintaining and servicing these critical components can be complex.

That’s where Rotec Hydraulics comes in. As a Parker Approved Accumulator Service Center (ASC), we possess the in-depth knowledge, experience and test rig facilities to provide comprehensive accumulator services, including: 

  • Product Range: We stock and sell accumulator products of all brands, sizes, and types.
  • Test Rig Facility: Our state-of-the-art test rig enables the testing of bladder type accumulators from 0.5 litres up to 54 litres.
  • Maintenance & Recertification: Our skilled engineers meticulously maintain and recertify your accumulators, ensuring optimal performance and extending their lifespan.
  • Pre-Charging & Audits: We pre-charge accumulators and conduct thorough audits to identify potential issues and prevent costly downtime.
  • Scheduled Inspections & Replacements: We offer customised inspection schedules and recommend replacements when necessary, proactively safeguarding your hydraulic systems.

Benefits of Choosing Rotec Hydraulics:

  • Enhanced Safety: Minimize accident risks and protect your employees with our expert service, adhering to all relevant safety regulations.
  • Regulatory Compliance: Ensure your operations comply with Pressure Systems Safety Regulations (PSSR) 2000 by adhering to recertification, data monitoring, and scheduled inspections.
  • Increased Productivity:
    • Boost Efficiency: Optimize system performance and reduce energy consumption with accumulator replacement, maintenance, and pre-charging.
    • Reduced Downtime: Minimize downtime and maximize productivity through warranty validation, preventative maintenance, and optimized performance.
  • Extensive Inventory of Accumulator Parts:
    • Bladder Kits
    • Charging Kits
    • Saddle Clamp Assembly
    • Relief Valves
    • Safety Blocks
    • Accumulator Flange Adaptors

Ready to optimize your accumulator management?

Contact us to schedule an initial consultation and discover how Rotec Hydraulics can help you enhance efficiency, improve safety, and minimise downtime.

Email sales@rotec.net or call 01823 348900.

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.