Minimising Downtime: Manufacturing Press Tube Replacement

Rotec’s technical team researched and implemented an innovative method to complete replacement tube pipework whilst keeping downtime to a minimum at a large car manufacturing plant in Gloucestershire.

Following damage occurrence on one of their press lines, the world-leading manufacturer required replacement Ø75×12.5 carbon steel tubes.

Traditionally, engineers would be required to remove the damaged tube in order to gather accurate measurements before being able to provide and fit replacements. The removal and installation processes would require manufacturer to shut down the machine during these times.

Downtime for a large manufacturer in the automotive industry can have huge implications operationally and financially. Always keeping the customer at the forefront of projects, Rotec’s technical team suggested using a 3D laser scanner to measure the pipework, in order to minimise downtime.

The 3D laser scanner not only meant that the machine no longer had to be turned off, but the measurements collected were incredibly accurate and minimised the influence of human error. Furthermore, the time required for Rotec engineers to be onsite removing pipes and then measuring them would be dramatically reduced – saving the customer costs due to reduced labour costs.

Once measured accurately, the design for new tubes created using CAD design software in-house at Rotec. In total, the measuring and design process was complete within 2 days.

Continuing Rotec’s commitment to utilising technologies, the tube ends were formed using the Parker HPF system, which eliminates the need for welding of the tube. Bespoke flanges were also machined to suit the formed profile of the Ø75mm tube and accommodate the bolt pattern of the existing connections. 

For more information visit www.rotec.net.

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 supports new immersive visitor experience at the Fleet Air Arm Museum

The Fleet Air Arm Museum will be wowing visitors with their new state-of-the-art, immersive Carrier Experience after a £1million refurbishment.

Rotec Hydraulics Ltd were pleased to carry out works on the hydraulic and electrical systems that are integral to the simulator experience at the museum, which houses aircraft and artefacts from the flying arm of the Royal Navy.

In addition to replacing over 50m of hydraulic hose, all hoses were uniquely identified using the Parker Hannifin PTS bar-code labelling system to ease traceability and future renewal. Rotec engineers also refurbished all hydraulic cylinders and repaired the two hydraulic pump units to ensure pressure and flow performance are maximised. Other works included replacement seals, filters and directional valves, strip and clean manifold assemblies and reservoir cleans.

Adjacent to the hydraulic works, Rotec carried out electrical works on the customer experience feature at the museum in the main pump room, remote control room and on the scissor lift which raises and lowers visitors during the simulation.

In the main pump room located control panel, Rotec removed existing obsolete Toshiba PLC unit hardware, and installed a newly supplied 24VDC 10A switch mode power supply module plus protective devices. A rewire the existing safety monitoring control relay and circuit was required to provide a dual channel redundant protective emergency stop circuit.

Rotec designed, supplied and installed replacement PLC hardware to replace the Toshiba module, which was then fully programmed with the required application specific logic code to ensure the scissor lift would rise and lower in time with the attraction’s audio-visual experience.

In the remote control room, Rotec supplied and installed an operator’s control station and local 24VDC power supply. The control station included a nominal 8” full colour touchscreen HMI device fully programmed with all existing and planned operator controls, indicators and alarms.

The works Rotec has completed in part of an overarching Carrier Experience. The new experience, which is dedicated to the memory of generous benefactor Vice Admiral Sir Donald Gosling KCVO, Vice Admiral of The United Kingdom, combines digital technology with the scale of a carrier flight deck to transport visitors from the pioneer years of the First World War, all the way to the modern HMS Queen Elizabeth class carriers of today.

Adam Gosling, of the Gosling Foundation comments,

“Vice Admiral Sir Donald Gosling KCVO, Vice Admiral of The United Kingdom founded the original Carrier Experience that opened in 1994 and has welcomed over four million visitors.

 

“To see the Experience reinvigorated and made meaningful and relevant for today’s audience is the perfect way to celebrate my late father’s enduring support of the Fleet Air Arm Museum. It reflects a mutual vision to preserve and showcase the proud history of British naval aviation. His generous legacy gift has enabled, once again, the illustrious tale of Britain’s aircraft carriers to be told, and enjoyed, for many more generations to come.”

Professor Dominic Tweddle, Director General of The National Museum of the Royal Navy says,

“The re-imagining of the Carrier Experience to include the Queen Elizabeth Class, the pride of the British fleet, demonstrates our ongoing commitment to the history of naval aviation and telling the story of the contemporary navy. This mix of heritage and modernity mirrors the projects that Vice Admiral Sir Donald Gosling KCVO, Vice Admiral of the United Kingdom so generously supported over the years.

 

“I am certain that the work of the staff team, contractors and corporate partner Lockheed Martin has brought to life the Carrier story in the way that Sir Donald had in mind when he made his legacy gift.  It is both an honour and a pleasure to recognise his lifelong support with this exhibition, which is housed in The Gosling Hall.”

Rotec were chosen to complete the works due to their impressive ability to combine hydraulics with complex electronic control systems. The works were completed in a matter of weeks, on schedule and to a high standard.

For further information on the expansive range of services Rotec offers, including case studies of other works, visit www.rotec.net.

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.

Rotec Celebrate as Double Finalists at the Somerset Business Awards 2022

Rotec Hydraulics Ltd celebrates being double finalists at this year’s prestigious Somerset Business Awards (SBAs) for ‘Best Use of Technology’ and ‘Somerset Manufacturer and Producer’ Award.

The awards, run annually by the Somerset Chamber of Commerce, received a record- breaking number of entries and only the most outstanding businesses with a head office in Somerset were named finalists.

Our investment and integration of Parker Internet of Things (IoT) technology earned us a place at the grand final in the ‘Best Use of Technology’ award category. IoT 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.

Named finalist for the ‘Somerset Manufacturer and Producer of the year’ category is testament to the team’s innovative development of several bespoke winch systems for both leading regional and national names within the Utilities sector.

Somerset Chamber Executive Director, Emma Rawlings, said,

“These awards are the largest in Somerset and are a fantastic opportunity to celebrate all that
is great about [Somerset’s] diverse business community.”

Paul Prouse, Managing Director, commented,

“Being named finalist in two categories is a testament to our team who have continued to provide solutions and outstanding products and services to our customers throughout a challenging period for all businesses.

“Investing in and utilising cutting-edge technologies and providing innovative solutions for our clients has always been at the heart of our business.”

The winners were announced at the Grand Final on 11th March, which celebrated the extraordinary organisations within the county of Somerset. Rotec finished as double finalists – a great achievement amongst such a high calibre of local businesses.

Pictured below (left to right): Roger Carne, Paul Prouse, Rachel Worth, Richard Lang, Mark Conniff, Josie Chamberlain, Richard Renfree and Andy Rimes.

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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.

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