Hose Test Rigs for the Motorsport Industry

100% Achilles audit _Rotec Hydraulics Ltd

Rotec Hydraulics Ltd designed, built and commissioned two identical hose test rigs for a UK manufacturer who supplies world-leading racing teams with fluid transfer assemblies, hose and fittings.

UKCA/CE certificated and labelled, the test rigs are designed to provide regular and rigorous testing for a variety of flexible hose assemblies. The rigs were based on an existing design, but updated and improved due to the obsolescence of some of the components.

Measuring over 3 metres in length, the main capabilities of the test rigs include:

  • Testing hoses up to four hoses at a time
  • Testing hoses up to 250bar pressure using water as the medium.
  • An air supply is used to control the hydraulic (water) valves and is used to pressurize the water using a 60:1 air/water intensifier.
  • A low-pressure pump provides a means of flushing and pre-filling the hoses under test.
  • Clean, filtered and dried compressed air supply of guaranteed continuous pressure of 6 bar minimum.
  • Power supply of 240VAC 1 PH 50Hz 16A maximum for UK use.
  • Nominal test sequence, based on existing rigs, (i.e., prefill/flush, test, vent, purge).
100% Achilles audit _Rotec Hydraulics Ltd
100% Achilles audit _Rotec Hydraulics Ltd

Each rig consists of a grade 316 stainless-steel upper half, and a powder coated steel lower half and electrical enclosure.

The lower half consists of the water reservoir, an air tank, an intensifier, a low-pressure pump, pneumatically operated hydraulic valves and a pneumatic control system. All the valves, which water flow through, high-pressure pipework & reservoir are made of grade 316 stainless steel to prevent corrosion. There are two lockable hinged doors on the front and three lockable panels on the rear to allow access for maintenance as well as internal led strip lights for enhanced lighting.

Inside the upper enclosure are eight ½” BSP ports (four either end) to which up to four hose assemblies can be installed for testing at up to 250 bar pressure. Bi-fold doors with transparent windows are fitted to enable access to the hoses, the doors are fitted with interlocks to ensure they cannot be opened whilst the hoses are under test. Internal led strip lights are built into the top of the enclosure to provide enhanced lighting. There is also a water filling point and drain which connect to a reservoir in the lower half of the rig.

Attached to the right-hand side of the rig is the Rotec designed lockable electrical enclosure which houses the customers electrical components. On the front face of the enclosure are controls for adjusting the test pressure, starting/stopping the testing cycle as well as an information screen displaying the results of the testing.

2 manually operated panel mountable air regulators were incorporated into the design. One is set and locked at 4.2bar inside the lower area (i.e., beyond the reach of the operator), the other panel mounted in the user control panel. This second unit is fed from the outlet of the former, ensuring the user cannot inadvertently set the test pressure to rise above the setting of the former and thus inadvertently (or intentionally) over-pressurise the system.

Rotec’s customer said:

“I am very pleased with the finished machine. As I expected, everything has been finished to a high standard.”

If you are interested in a similar project or any hydraulic power systems, do not hesitate to contact the team today on 01823 348900 or email sales@rotec.net.

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.

Rotec’s repair and overhaul service reduces running costs by 10% at leading manufacturer

Machine prior to overhaul
Overhaul completed, outer door refitted and ready for re-paint

Following a major failure during operation, a large flooring, MDF and OSB manufacturer asked Rotec to carry out extensive repairs on an industrial wood chipper.

Owing to the failure occurring whilst the machine was in use, the Maier Wood Chipper machine had suffered severe damage internally and so required a thorough repair and overhaul service.

After Rotec engineers stripped the machine and checked all components, it became apparent that the shaft bearing sleeves had failed, worn the housing and as the blades had come away during the failure, many internal parts were damaged and required either replacement or upgrading.

As the customer had issues with levelling up the impellor blades, Rotec checked the laser alignment and then ‘clocked’ the rear datum locating ring support pads on the machine. The support pads were found to have a 0.7mm difference in their positioning which, may have been a contributing factor to the issues leading to the initial failure. On discussion with the client, it was decided to build up the lower blocks and design and build a tool for machining the pads in-situ.

Once the chipper had been repaired, overhauled, re-painted and fitted back onsite at the customer’s facility, the client was so pleased with Rotec’s workmanship and project management that Rotec have now taken delivery of another unit from the same workshop for a complete overhaul.

The Engineering Managing of the flooring, MDF and OSB manufacturer has since reported that the overhaul and rebalancing of the machine is so good that the company is achieving a higher output rate and saving 10% on the machine’s previous running cost.

Laurence White, Business Development Manager for Rotec Hydraulics Ltd, commented;

“It has been a pleasure to be part of this thorough overhaul and repair service. Our team take pride in knowing that we have delivered a high level of workmanship and have not only helped to increase efficiency, but also have helped to reduce running costs for our client. We look forward to a long lasting relationship with our customer.”

For more information regarding Rotec’s capabilities, including the overhaul and repair service, contact sales@rotec.net or phone 01823 348900.

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.

Ground-breaking Project successfully crosses the Atlantic Ocean

A pioneering project, supported by Rotec Hydraulics Ltd, has achieved a fully autonomous ship sail across the Atlantic Ocean.

Solo and unaided, the Mayflower Autonomous Research Ship (MAS) set sail from Plymouth harbour in the UK and reached its end destination of Plymouth USA on 30th June 2022 after 36 days at sea and 3,900 miles, having made two stops in Horta (Azores) and Halifax (Canada).

The futuristic vessel was powered by AI and powered using renewable solar energy technology, and a backup diesel generator for night sailing. Throughout the journey, the vessel collected data that researchers hope will provide critical information in the battle to safeguard the future of our oceans. A challenging project relied on a diverse team that spanned 10 countries and 3 continents, including Rotec Hydraulics Ltd.

ProMare, a US based non-profit organisation with a branch in Plymouth UK, teamed up with IBM to build the third Mayflower and asked Rotec to supply a range of hoses and hose assemblies to support the project. Rotec was also pleased to be able to help spread the word of crowdfunding efforts at the start of the project.

Brett Phaneuf, Managing Director of the MAS Project, commented:

 “[The Mayflower Project is] ushering us into a new phase of oceanographic and climatological research with state-of-the-art technology.”

Paddy Dowsett – Project Manager, MSubs says:

“This project brings a number of new  technologies together in a way that hasn’t been done before. There are some smaller autonomous crafts in existence, however nothing anywhere near this scale in terms of size and technicality.”

Find out more about the project, including live video stream when the vehicle is on a mission and footage from previous journeys at https://www.mas400.com/.