Preventive Maintenance

1
Preventive Maintenance

• www.hydraulico.com

2
Goals

• Increase uptime
• Reduce unplanned production interruptions
• Maximize budget dollars
• Increase employee confidence

3
Benefits

• Reduced labor rates
• Priority scheduling

4
Overview

• Hydraulic
• Electrical
• Mechanical
• Safety
• Datalogging

5
Hydraulic

• Visual inspection of all fittings. Tighten as
  necessary. Determine cause for any leaks, change
  O rings for any pipe leaks.
• Take oil sample from reservoir and analyze.
• Change all oil filter cartridges.
• Take readings from all pressure check points.
  Make adjustments if necessary.
• Confirm cooling system operating in accordance
  with specification.
• Change air breather cartridge.

6
Electrical

• Inspection of control cabinets to ensure tight
  wire and component connections.
• Test all limit switches
• Verify control interface program pages for proper
  operation.
• Monitor all motor voltages and amperage readings.
• Monitor proportional valve amplifier card
  voltages.
• Hydraulico-Inc. will verify and record all
  power-supply voltages AC and DC and incoming line
  voltage. Adjust if out of /-5 tolerance range.
  These checks are made in both the static and
  load conditions.

7
Mechanical

• Check all bolt connections between cylinders and
  ram. Tighten where necessary.
• Hydraulico will inspect the condition of the
  gibs. We will look for pitting, scoring or any
  wear areas.
• We will inspect all cylinder rods, including the
  ejector for leaks, scoring, and or pitting

8
Safety

• Safety Manifold (Counterbalance) Validate
  proximity switch settings and operation.
• Mechanical Guards Ensure all mechanical guards
  and barriers are intact and the electrical
  interlock switching is operational.
• Two Hand Control Substantiate proper control
  operation.
• Light Curtain Test for proper operation. This
  check dovetails with Stop time checks.
• Ram Lock Test proper operation of ram locking
  pin device.
• Emergency Stop Functions Verify all E-stop
  circuits are operational.
• Hydraulico will conduct a test on the stop time
  that will consists of a 12 point measuring test
  on channel 1 and a 12 point test on channel 2
  that will document the ram stopping time. This
  time will then be used to compute the proper
  safety distance for the operator. We will also
  make any necessary adjustments that are required.

9
Preventive Maintenance Contract Advantages

• The maintenance measures can be planned to a
  large extent
• Maintenance and production plans can be agreed
  upon
• The demand of spare parts can be specified in
  advance
• The downtimes tend to be shorter
• Reduced production downtime, resulting in fewer
  machine breakdowns
• Better conservation of assets and increased life
  expectancy of assets, thereby eliminating
  premature replacement of machinery and equipment
• More economical use of maintenance workers due to
  working on a scheduled basis instead of a crash
  basis to repair breakdowns.
• Timely, routine repairs circumvent fewer
  large-scale repairs.
• Reduced cost of repairs by reducing secondary
  failures. When parts fail in service, they
  usually damage other parts.

10
Advantages, continued

• Reduced product rejects, rework, and scrap due to
  better overall equipment condition.
• Identification of equipment with excessive
  maintenance costs, indicating the need for
  corrective maintenance, operator training, or
  replacement of obsolete equipment.
• Improved safety and quality conditions.
• Reduced overtime

11
Optional service Data logging

• Increase the production output by optimizing the
  speed of the press cycle.
• Reducing scrap because you can see and correct
  the invisible failures and instabilities.
• Reduce down time and extraordinary service cost
  due to prediction of coming failures.

12
Data logging Sample

• BLACK Actual Pressure Back cylinder
• RED Actual Pressure Left cylinder
• GREEN Actual Pressure Right cylinder
• BLUE Actual Pressure Front cylinder
• BROWN Signal for amplifier card back cylinder
• PINK Signal for amplifier card right cylinder
• RED/BROWN Signal for amplifier card back
  cylinder

13
Datalogging may reduce cycle time by

• Verifying pressures are smooth and stable
• Visually seeing delays as pressure builds
• For settings that are being reached, see HOW it
  is reaching the desired point

14
Data Logging Benefits

• Improved Blankholder Control
• For unstable pressures, data logging enables
  Service Technician to isolate the reason, adjust
  and/or change a component, blankholder control,
  improving scrap rate and quality.
• Seals and Packings
• Data logging can indicate problems with pressure
  holding at the preset value, indicating that the
  seals in the cylinders may be leaking.
• Valves
• Data logging will reveal change in valve
  performance, or slow performing valves, resulting
  in excessive wear and slower production.
• Programming
• Data logging can reveal slow relays and slow PLC
  signals, and signal malfunctions to minute to
  see, or too intermittent.

15
Thank you for watching this presentation

• Hydraulico a/s
• Postbox 185 Raadhusgade 87 8300 Odder
  Denmark
• Tel. [phone] Fax [phone]
• E-mail info_at_hydraulico.com
• www.hydraulico.com