Dummy Bar Disconnect Cylinder Upgrade
IRG improved the average duty cycle of cylinder from weeks to over a year!
Customer:
Steel ProcessorIndustry:
Steel IndustryEquipment:
Caster Dummy Bar Disconnect CylinderServices Provided:
Hydraulic System Design, Upgrade, and InstallationResults:
Cylinder average duty cycle improves 300%+, Cylinder replacement time decreased by over 50%
Summary (Problem)
A steel processor was experiencing hydraulic cylinder failure on the caster dummy bar disconnect cylinder. Failures were so common and repair times so lengthy that three spares were required for one operating unit.
The hydraulic equipment was observed in operation and production and maintenance personnel were consulted as part of IRG's hydraulic troubleshooting process.
Process and Outcome
A course of action and hydraulic system re-design plan was created, which included:
- Redesign of rod end to allow for easier disassembly
- Typical rod end removal required more than eight hours
- Redesign of the rod-bearing gland
- Increase load-bearing area
- Material change
- Redesigned seal cavity dimensions and configuration
- Redesign Cylinder head, rod end, and rod gland water cooling system
- Installation of anti-rotational mechanical device to insure rod end registration
Results:
- The cylinder average duty cycle went from weeks to over a year.
- Removal and Replacement time of the cylinder was decreased by 50%+