Unique Hydraulic Solution Saves Steel Manufacturer Up To $96K Annually

System Overview: A loading table had seven stop arms that were kept raised as product accumulated and were then lowered to allow product to be transferred. The arms were raised and lowered by a back-to-back cylinder whose position was maintained by load locking checks. The process required close interaction with an overhead crane that would sometimes hit the arms and explode the cylinders. Annual cylinder usage was 30-40 / year at a parts cost of $2,000-2,500 each. Annual loss $60,000-$100,000.

Scope: IRG was asked to troubleshoot and find a solution to reduce cylinder repairs and repair costs.

IRG came up with a unique and innovative solution. While the cause of the cylinder failure was overpressure a relief could not be used as the arm was required to stay up during the operation. IRG installed an accumulator on each cylinder to provide a space for fluid displaced as the arm was struck by the crane and then, send the fluid back to the cylinder and return the arm to vertical. Total Turnkey Cost $23,000

Results: Cylinder repairs have not exceeded 3 / year with an average Cost < $1,200 each compared with the previous annual cylinder usage was 30-40 / year with an average cost of $2,000-2,500 each.