5 Reasons Pumps FailJanuary 12, 2024
Identifying Problems with a Customer's Existing Hydraulic System
Our Motion Repair & Services team was recently asked to perform hydraulic repairs for a long-time Canadian flour mill customer. This hydraulic system was responsible for mixing flour for the company’s boxed mixes.
This dated system required manual flow control adjustments of hydraulic auger motors. To perform these adjustments, an employee had to climb onto a catwalk above the machinery throughout the day. Despite this, flow control was still often inaccurate. This system also required diligent maintenance to keep flour from entering the system’s oil, which could cause a multitude of system errors.
Upon hearing how frustrated the customer was with their existing hydraulic system, our team made a recommendation to the customer. Rather than simply repairing the existing system, we recommended that the customer allow our team to create a custom electromechanical solution to replace their hydraulic system.
Converting Hydraulics to an Electromechanical Solution
Our Motion Repair & Services team supplied this customer with an electromechanical drive package, installing and retrofitting the solution. This electromechanical system was designed to provide the customer with variable frequency drive (VFD) control for each of their 18 augers. It also provided the customer with a programmable logic controller (PLC) and a touchscreen for a simplified operator interface and the utilization of batch recipes. The control panel included an air-purged, explosion-proof enclosure to comply with area classification.
Overall, the customer is very pleased with their electromechanical system. Now, rather than climbing on a catwalk to manually adjust flow control, operators can set up automated premixes by pressing a button. The customer has also increased their loadout capacities and speeds by 28% while improving overall reliability, efficiency, and automation.
“Our shop really stepped up and did a great job on the creation and installation of the solution,” said Ian Miller, Motion Service Shop Manager. “This is the type of customer we work closely with and who comes to us for their daily needs. We’re currently evaluating automated lubrication systems for some of their other mills to be installed in the near future.”