From the start of my engineering career maintenance was an essential element in my mechatronic apprenticeship – if we do not maintain equipment, the risk of premature and unexpected failure is certain.
Demands of modern-day manufacturing processes
Component and machine manufacturers invest a colossal amount of money and time in the design and testing of their parts to ensure they meet the demands of our modern-day manufacturing processes.
Key information for all maintenance managers is the expected mean time between failure. This information is often available from suppliers and enables planning to prevent failure in the production lines. Does your company use data to prevent breakdowns or catastrophic failures? Most do not.
A planned maintenance schedule is aimed at avoiding unexpected breakdowns and failures. It is designed to preserve and enhance equipment reliability by replacing worn components before they fail.
Data capture and predictive analytics using smart sensors can measure small changes in machine characteristics and assist with the prediction of possible failure. This gives the maintenance manager the best chances to optimise the uptime of equipment.
An example is the CO.RA. Rotary Valve designed for applications where a continuous flow of powders and granules pass through to the next process, half-body design to assist with the removal of component parts for cleaning and maintenance, reducing the time taken for out-of-service cleaning.
Depending on the media being processed, and the material of seal used, CO.RA. recommendations to the service life of the sealing material can vary, (just like the tyres on a car), and over time they wear and need to be replaced.
If not, this could lead to a puncture and result in a breakdown, or even worse, a catastrophic failure and result in permanent damage, with new hardware required (the more expensive option).
Axial loading
Bushing material carries axial loading, which supports the shaft of the rotor, periodic inspections will build up a history of wear and determine when replacement parts should be fitted.
Inspection intervals should be no more than six months depending on usage. If not inspected and metal on metal contact takes place, most times the damage is unrepairable and new assets are required.
Actuators are a fundamental part of the automation process, whether pneumatic or electric. They are precision engineered equipment, having various moving parts, pneumatic actuators require compressed air to function.
Clean, filtered air is required, and on many occasions filters are not replaced during maintenance. This is an essential spare in my opinion – contaminated air entering into the chambers of the actuator, such as dust and dirt particles, will cause premature damage to the seals and bore of the actuator. If your filters are discoloured in any way, you have contamination in the system.
Electrical connection testing is another essential part of planned maintenance. Every six months a panel inspection should be carried out, along with a terminal tightness test.
Troubleshooting is a skill acquired over many years: personal experience and plant knowledge go hand in hand, the more experienced the engineer, normally the faster they will locate the problem.
Invest your time in Planned Preventive Maintenance, and save on the unexpected breakdowns.
Further information
For further information on CO.RA. products visit www.flexachem.com
Flexachem Ireland has an extensive track record of customer support throughout all sectors of industry, which includes site services, stock, technical specialists and upskilling training. Contact Flexachem to discuss your ongoing maintenance requirements – often our stock caters for an unexpected breakdown.
Contact our valves team: External support engineer: Brendan Merrigan E-Mail brendan.merrigan@flexachem.com Tel +353 (0)872598124
Or any of our internal specialists:Tel +353 (0) 214617200 www.flexachem.com