Problem: A large Salt manufacturer needed to hydraulically control a new massive diverter system. Salt water, highly corrosive environment. Very tight time line

Solution: A large 120 HP, Coast Guard approved (for salt water environments) hydraulic system with dual pump redundancy was designed, assembled and installed, controlling all diverter movement (up / down/ rotate 360 degrees) via either an operator pendant, or PLC. On budget. On time.

 

Problem: A large rolling mill had tremendous reliability and leakage troubles on two critical hydraulic power units. Work related injuries were troublesome, as were productivity issues.

Solution: Both hydraulic units were surveyed, determining that low hydraulic level alarms, high efficient filtration and cooling were needed, plus all old hose and seals replaced. Both units were thoroughly steam cleaned, drained of all hydraulic coil, all seals and hoses replaced, new oil added, new filtration, low-level alarms and coolers added. All were placarded and then fully repainted. Before and after photos are included here.

Problem: A space launch facility needed to open two 40’ x 80’ x 3’ blast doors, allowing the space launch vehicle to exit the assembly area to the launch site.

Solution: Two very large rotary actuators, and the needed 5,000-psi hydraulic system were designed, assembled and delivered. Each rotary actuator was mounted 80 feet up, on top of each blast door, rotating each door 195 degrees. All operator controls were via a pendant and / or PLC.

Problem: A protective Armor Company needed to apply 600+ tons of force to their product, holding it for over 15 hours at a time. Load needed to ramp up in 100 pound increments. Very high heat. Very corrosive environment.

Solution: A 14” bore x 5,000-psi tie rod cylinder was designed, along with the needed servo controlled 5,000-psi hydraulic system. Touch screen and / or remote PLC controlled. On time, On budget.

Problem: A Security Company that makes identification cards for high security areas needed to apply over 500 tons to their product, pressing and ejecting every 6 seconds.

Solution: A 8.0” bore x 6,500-psi tie rod cylinder was designed, along with the PLC / servo controlled, 7,000-psi hydraulic system. Excess heat was removed via PLC controlled coolers. Low noise (75 db, levels attained. On time, On budget.

 

 

Problem: A customer’s primary large hydraulic cylinder blew a main seal. 100+ employees were out of work with this cylinder down. The OEM factory could not provide the needed replacement parts for 3+ weeks.

Solution: A Gulfstream Jet was commissioned to fly to twelve (12) locations around the country, acquiring the needed replacement parts for the emergency cylinder repair. The cylinder was repaired and re-installed less than 23 hours after failure.

 

Problem: A specialized jean manufacturer received an order for thousands of ground-up blue jeans. The manufacturer needed to build 25 custom machines that the blue jeans could be put onto, allowing workers to grind away as required per contract.

Solution: All needed air cylinders (4 different ones per machine – total of 100) were designed, assembled and delivered within 6 working days of the original call for help. The manufacturer was able to assemble all 25 machines within two days later, and delivered the needed blue jeans that next week. The manufacturer eventually assembled over 150 exact blue jean-grinding machines.

Problem: A large rolling metal painting company had purchased a decommissioned automatic paint line back east and needed it reinstalled here in Southern California.

Solution: All 25 hydraulic stations, and 65 pneumatic stations were identified, upgraded to new equipment, and plumbed with stainless steel. Total start-to-finish time of this huge installation was 45 working days. No leaks, no startup troubles, on time and on budget.

Problem: A large metal conduit company needed to routinely sort, stack and bundle various lengths of new conduit. Lengths of 15, 25, 45, and 60 foot were to be used.

Solution: Four (4) large scissor lifts were commissioned, to accept the flying conduit as chosen by the company’s photo eye technology. The scissor lifts would lower a small amount as each conduit was stacked upon it. All four (4) scissor lifts had to lift and lower, in harmony, = or – 0.125 inches. All hydraulics were controlled by either an operator pendant, or PLC. On time, on budget. Heavy-duty equipment, in a very dirty and oily environment. Reliability and safety were of prime concern.

Problem: A movie production company needed to remotely mount a camera upon a moving vehicle, and have the camera swing 180 degrees around the front or back of the car. There can be no shaking or jerking due. Delivery was needed within 6 working days, over the Christmas Holidays.

Solution: A 12 VDC powered, suitcase powered, servo / pendant controlled hydraulic system was designed and delivered within 5 working days. The system went to Italy for a large Mercedes Benz advertising shoot, with the hydraulic system proving to be bulletproof. The swinging camera shots, from the moving vehicle are now an industry standard.

Problem: A major beverage manufacturer runs the operation literally 24 / 7 / 7 with one week per year scheduled for maintenance (January 1-6). This customer’s case packer machine (takes the canned beverages and places the 6-packs into 24-pack cases), was having terrible downtime issues, specifically due to lack of lubrication.

Solution: The 125+ point automatic lubrication system installed originally from the factory was inoperative. Over 3+ days, each individual lubrication point was identified, it’s specific problem was solved, new grease / oil lines were run as needed, all defective parts were replaced and the system has performed flawlessly for over 3+ years now.

Problem: A large cake baking company was mandated by the FDA to properly identify all cake boxes with date, time, and production line information. The customer chose a laser identification system, however there was no way to move the boxes through the laser system.

Solution: Two (2) separate, PLC controlled conveyor systems were designed, fabricated and delivered. All stainless steel construction. On time, on budget.

 

Problem: A brick-painting machine (tumbles the brick with paint to give it the weathered look), continued to shutdown, causing 35+ employees to be out of work until it was repaired. Overheating, very high noise levels, and hose reliability were all causing continual problems:

Solution: Over a two day period, the noisy hydraulic pump / motor were replaced with new. All 44+ hydraulic hoses were replaced with new. A new heat exchanger, and higher flow hydraulic valves were replaced with new. System has operated 3+ years without any troubles. Noise levels have fallen to below 75 db, and electricity costs have been cut in half due to higher efficiency pump and motor.

Problem: A manufacturer uses 12 ‘ high x 5’ diameter tubes in their manufacturing process. These tubes are filled with powder, heated to 2100 degrees F., and pressed to over 400 tons. Each tube is mounted upon a small railroad cart. Prior to the material being pressed, the railroad tracks are lowered 1.0 inches to lower the cart onto the concrete platen. During the lowering and lifting process, the existing system would tilt, shake and twist the tall tubes, with the very high possibility of the tubes falling. A falling tube would collide with another awaiting tube cart, causing a domino effect for all 20+ carts. This could be catastrophic.

Solution: A new hydraulically controlled, railroad track lifting system was designed, fabricated and installed. The tracks now lift and raise solidly, with no twisting, shuddering or tilting. Also, due to manufacturing constraints, the entire system had to be removed and installed within 12 hours. On time, On budget. Two (2) plus years in operation with not a hiccup, leak or failure.

Problem: A major concrete pipe manufacturer’s rolling tables could not be controlled precisely. They would start and stop in all the wrong places, causing additional manpower hours to physically move the 50’ x 35’ tables back into place.

Solution: A PLC driven, servo control hydrostatic transmission drive system was designed and installed. Now the table moves precisely, and stops within 0.15” of the desired position.

 

Problem: A major seafood-processing house needed to drive and synchronize six hydraulically driven conveyors. Salt water environment, 24/7 operation, and extreme cold.

Solution: A small hydraulic system (stainless steel with heater) was designed to drive the conveyors. Simple Pressure Compensated flow controls were added to each motor’s outlet flow, along with individual shut-off valves, allowing the Operator to effectively shut down an individual operation, and / or precisely meter the speed of each conveyor, regardless of how many fish were dumped upon it.

Problem: A manufacturing company was losing 2 hydraulic pumps every other month on two large presses.

Solution: After surveying the equipment, it was determined that high contamination levels were killing the pumps. Ultra-fine particulate filtration was installed in both the return and high-pressure lines, eliminating the abrasive material that was killing the pump. Pump reliability is now over 4+ years.

Problem: A metal turning company’s primary metal roll holding machine had failed. Over 15 employees were out of work until it was repaired. The original equipment manufacturer was no longer in business.

Solution: The defective part was reverse engineered and made from new steel. The existing rotating coupling assembly was removed and repaired. All was reinstalled and running within 2 working days.

 

Problem: A large Mineral processing plant uses a 35’ x 15’ rolling drum to process their material. This drum is driven by a large electric motor turning a very large (15 ft diameter) gear assembly. This gear assembly needs to be constantly lubricated to prevent dirt ingression and failure. Over 75+ employees are out of work if this tumbler ever goes down.

Solution: A Lincoln Automatic lubrication system was designed, fabricated and installed within the rotating gear assembly. Heavy, tar-like grease is literally sprayed onto the rotating gear, 24/7, keeping it properly lubricated and dirt from entering the system.

Problem: A large white rock processing plant uses huge rock crushing machines to literally pulverize rock into a fine dust / powder needed for their processes. These massive rock crushers are extremely loud and very dangerous, however they need to be lubricated every few hours or else they destroy themselves. This presents a very unsafe environment for any person to apply lubrication.

Solution: A Lincoln Automatic lubrication system was designed, fabricated and installed, to provide high-pressure grease, injecting it into the needed lubrication points. All automatically completed, and monitored via remote PLC / Operator control station s to low grease level, no grease received, and / or no power to the equipment.

Problem: A major mineral processor needed to supply heavy, tar-like lubricant to a critical rotating gearbox. Current pumps were failing every 4 weeks due to viscosity and temperature issues.

Solution: A new pump / motor solution was designed and delivered, providing correct lubricant flow levels, while operating in an extremely cold environment. A total of eight (8) systems were delivered. Over 5+ years of reliability.

Problem: A major gas pipe manufacturer was having major failures and leakage of two critical hydraulic tube-cutting machines. Down time was killing production: Also their staff knew nothing about the machine, or how to work on them to repair.

Solution: Both machines were surveyed, with a following proposal to clean up the machines, replace all hydraulic hoes with new (16 x 1.0” ID), repair all leaks, repaint and placard the machine with identification tags, install a low-oil alarm system, digitally photograph and identify all major components, document the exact systems and parts upon the machine and training all staff members. Total down time was less than 6 hours, all staff was trained and production continues 3+ years.

Problem: A tooth cap manufacture needed to speed up production levels from 10 tpm to upwards of 100 tpm, plus be able to “shift-on-the-fly” from one tooth style to another.

Solution: A PLC driven, servo controlled hydraulic / electrical system was designed, fabricated, installed and tested. The customer could quickly reload new software, causing the hydraulic machine to press at different strokes, speeds and pressures, all automatically. Tooth per minute rates climbed to 125, with all parameters testing successfully. Sadly, the design engineer left the company and all further testing was halted.

 

 

 

 

 

Problem: A roofing tile manufacture uses finely crushed dirt in the process. Large rocks need to be broken down into smaller sizes, allowing the to literally fit into the large rock crushers. Hydraulic Hammers are used for this process. Very dangerous, and awesome devices. Hydraulic hammers must be lubricated every ½ hour or they will destroy themselves. This presents a very unsafe environment for a person.

Solution: A large, Lincoln automatic lubrication system was installed to effectively lubricated the hydraulic hammer, and it’s corresponding mounting arm’s 20+ lubrication points. This eliminates the need for any person to be near this destructive machine, yet effectively protects the very expensive equipment.

Problem: A carbon process plant uses 100-300 yard long conveyors and diverters to move the carbon powder to awaiting ships. These conveyor tunnels are dark, damp, below sea level and are very dangerous. This customer’s existing 63 station hydraulic system was failing repeatedly due to defective (worn-out) hoses, valves and fittings.

Solution: All 504 (63 x 8) hydraulic hoses, 63 hydraulic valves, 504 hydraulic fittings were replaced with new. The hydraulic system was upgraded with ultra-fine filtration and air breathers. Total down time was less than 3 working days. The system startup went flawlessly (no leaks), and is still troubles fee 3.5 years later.

Problem: An aircraft parts manufacturer uses a 800-ton press to push down upon metal, expanding it into the needed aircraft part. Backpressure of 300 tons is needed behind the mold being pressed upon, to hold the shape of the part being made. The customer could not adequately maintain the needed backpressure.

Solution: The existing 14” bore cast iron, single acting hydraulic cylinder was disassembled, repaired and reinstalled. A new, servo controlled hydraulic system dedicated specifically to the backpressure side of the huge press was designed, fabricated and installed. Backpressure can be monitored via PLC, and remotely raised or lowered as needed for the specific part. On time, and On budget.

Problem: A Huge CAT 365C Excavator was mistakenly ordered without an automatic lubrication system (21 points). Without this system, production losses were incurred to manually lubricate the CAT 365c.

Solution: A Lincoln (OEM with CAT) automatic lubrication system was designed to work with CAT’s own on-board computer control system, providing the needed lubricant to the 21 points. Cost savings to the customer (vs. a CAT installed system) was over $5,500.00.

 

Problem: A paving stone manufacturer uses two large, complex, servo controlled, German built hydraulic presses. These presses continue to overheat, leak badly and cause tremendous production / downtime issues.

Solution: Each press was physically surveyed, heat gun readings were taken at all 15 hydraulic manifolds, digital photos were taken, and copies of original hydraulic schematics were reviewed. A two (2)-stage proposal was accepted, with Stage 1 being the above survey and analysis. Stage 2 included all needed repairs and / or upgrades to eliminate the troubles. On time, and On budget.

Problem: A large brown paper manufacturer uses a very large German made hydraulic pump in their processing department. This pump is no longer available from the manufacturer and only one (1) spare was available. Upgrading to a new style pump would involve major structural and facility changes. Then the pump died.

Solution: The old pump was immediately removed and replaced with the spare pump. The dead pump was disassembled to determine root failure cause (dirt / heat). New parts were reverse engineered, installed and tested. All performed as designed, with the customer now having a reliable spare pump again.

Problem: A major oil refinery used a massive hydraulic system to control six (6) major chute controls. These chute controls (12 large cylinders each) continued to fail, jeopardizing men’s lives due to the extremely hazardous location, very high heat, and leaky hydraulic oil.

Solution: Until major plant redesigns could be completed (3+ years away at the start of the project), each week a trained hydraulic technician would walk each and every portion of the existing hydraulic system, giving recommendations of repair to the oil refinery. A normal workday would consist of the walk around, change out of 2-3 leaky cylinders, 1-2 leaky hydraulic hoses and fittings, plus cleanup. System reliability skyrocketed. Systems hydraulic leaks dropped dramatically, and no one was getting hurt anymore. This contract lasted for 127 weeks until the redesigned plant could be built.

Problem: A major food processing manufacture continued to destroy hydraulic motors. These motors are used in a stirring process.

Solution: Upgraded, epoxy coated hydraulic motors were installed. System reliability went from 5 weeks to 125 weeks.

Problem: A major bakery was losing the main oven chains every few months. These stainless steel chains are very expensive and time consuming to replace.

Solution: A Lincoln automatic chain lubrication system was installed, using very high temperature, food grade oils. Chain reliability has skyrocketed.

 

 

Problem: A major city college recently built an all-new automatic school. The automotive school uses high pressures air and water for various automatic functions (air tools, tire filing, coolant recovery), yet nothing had been planned except overhead pipes. The students could not utilize the piped air or water supplies.

Solution: Twenty four (24) individual Lincoln hose reels were installed at the school, allowing the students access to the needed compressed air and water. Air hoses were color-coded red. Water hoses were color-coded blue.

Problem: A huge harvester machine utilizes hydraulic power to control the speed of each conveyor. The machine kept destroying various conveyor components due to over pressurization of the hydraulic system.

Solution: A complex hydraulic relief manifold was engineered, fabricated and installed (2.0” hydraulic hoses, 6,000 psi), allowing the main hydraulic motors, if over pressurized, to relieve the hydraulic pressure immediately at the motor, instead of the pressure having to spike and be relieved back at the main power supply.