Hydraulic Press Automation System Repair

A manufacturing company in Morrison, TN, needed repairs for its ageing hydraulic forming press. This 40-year-old machine was an impressive dual-action device that shapes two separate parts simultaneously.

This process significantly boosts production yield compared to simpler machines that shape one part at a time. Furthermore, it requires more than just an automated system since multiple operations must be controlled simultaneously for tight tolerances.

Identifying the Problem

When your hydraulic press requires repair, it's essential to identify the issue. Knowing what caused any issues will allow the repair team to address them promptly and effectively, saving your company time, money, and avoiding unexpected downtime.

Many presses experience a leaky pump plunger due to an unstuck packing nut. This can easily be fixed by tightening the nut.

Another potential issue is a leaky piston oil seal. This could indicate that the piston packing has become worn or damaged.

Hydraulic drift can also be caused by contaminated hydraulic fluid. This could lead to clogs in hydraulic pumps, leading to system pressure losses.

Preventing hydraulic drift requires regularly inspecting cylinder pistons for corrosion that indicates they should be replaced. Furthermore, inspect hoses regularly for cracking or unusual crimping as these issues will directly impact production capacity of your press.

Disassembly

Repairing hydraulic presses can be a time-consuming and costly endeavor. This is because many components, such as press cylinders or HPU hoses, may break down during use and necessitate specialized tools to disassemble.

Thankfully, automated technologies can help manufacturers reduce cycle times and boost consistency. That is to say, presses designed just a few years ago can be retrofitted with automation technology, requiring them to use fewer operators and reduce downtime.

A common tool used for this task is a disassembler. This converts code into an assembly language file which can be easily viewed and examined.

Another useful tool is a dynamic disassembler, which displays line-by-line the real time execution of machine instructions. This provides valuable debugging data.

For this project, we rebuilt the press automation system and programmed its force to match preset movements. Additionally, this PLC-based control reversally steps the press based on measured pressure; ensuring part uniformity and extending machine life.

Parts Inventory

When hydraulic press automation systems are repaired or rebuilt, it's essential to inventory all parts that were taken apart. These items should then be classified and added to an inventory control system so they are easily accessible when future servicing of the machine requires them.

MaintainX provides a robust spare parts inventory management system that can be tailored to suit your specific requirements. It features features like synching parts with work orders, setting low stock alerts, calculating inventory minimums and tracking usage probabilities.

Maintenance managers use inventory tracking to anticipate their spare part needs and order only what is necessary. This streamlines the ordering process, cutting down on unnecessary inventory and thus decreasing overall costs.

A comprehensive parts inventory management system can organize a complex parts tracking process and offer tools to streamline operations, save labor, and highlight areas needing improvement. It integrates with other software packages, reduces manual data entry, and makes inventory tracking much simpler.

Rebuild

Hydraulic press automation system repair involves rebuilding or replacing components that drive the mechanical, electrical and hydraulic systems of a press. This helps increase efficiency while decreasing wear-and-tear on the machine.

Rebuilds typically involve installing new controls, rebuilding or replacing hydraulic manifolds, valves and pumps with modern components for extended, more efficient performance of the equipment.

Closed-loop distance and pressure capabilities enable improved accuracy, repeatability and part uniformity. They also permit faster cycle rates as well as the control of difficult-to-form materials.

The newly designed press control allows operators to set and run recipes for each job with just one push of a button, making the machine simpler to operate and providing more flexible production - leading to higher production rates and superior quality output.

Southern Manufacturing Group (SMG) of Morrison, Tennessee needed to retrofit its 175-ton hydraulic forming press and automation system after lightning damaged the facility. SMG needed the work completed quickly so it could continue producing parts and keep up with its production schedule.