CFP Hydraulic Systems Ltd

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Case Studies

Case Study 1. Hydraulic Power Packs and Systems for Rubber Extrusion Machines

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A Japanese manufacturer of rubber extruded components set up a new manufacturing plant in our area. Our long established customer, specialist machine builders Glenborough Engineering, were contracted to reproduce machines based on Japanese designs, but to meet CE requirements. CFP supplied complete hydraulic systems for a number of 17-ton extrusion machines.

At the heart of the hydraulic system were ATOS variable displacement piston pumps with proportional flow and pressure control allowing the machine to be driven by a 5.5kW motor instead of the 11kW which would have been necessary if the maximum flow and pressure was to be made available from a standard pump.

CFP also supplied Miller Hydraulic rams, Char Lynn hydraulic motors and ancillary equipment by other manufacturers to complete the build of the machines.


Case study 2. Engine Driven Hydraulic Power Packs

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Balfour Beatty Power Transmissions division use power packs to deliver a pressure of 520 bar. The packs being used were causing problems with overheating. CFP were asked to investigate the availability of alternative Hydraulic Power Packs and systems which would solve the problem.

In investigating the cause of the overheating, it was discovered that the tool operators left the manual control valve in an operate position. Manual valves operating to 500 bar and higher with spring centering are rarely available and very expensive. Our solution was to design a hydraulic system which would unload the pump if the operator left the manual valve control handle in an operate position. Dynex Rivett manufactured the pumps and pressure control valves used; the engines were by Hatz GB. A tubular steel-lifting frame was manufactured to carry the engine, pump and reservoir with the hydraulic system unloader internally fitted, enabling the power pack to be transported by various means.

Similar hydraulic power packs were produced for EVE Tramscom but Honda Petrol engines drove these power packs and the pumps are HAWE radial piston type.


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Case Study 3. Hydraulic Power Pack System Operating Boiler Gas Diverters

Boiler gas diverter manufacturer Whalco required three power packs to operate in a gaseous atmosphere, which controlled the position of a gas diverter blade, and had an emergency back up which operated the blade in the event of power failure to the rig. The frame was made of stainless steel, the electric motor, solenoid valves and pressure switches were Eexd certified for use in explosive atmospheres. A 10 lire bladder accumulator stored the volume of oil at pressure for the emergency operation of the cylinders. All pipe work was in metric OD stainless steel pipe and Walterscheid fittings. ATOS manufacture the solenoid valves and the filters are by MP Filtri.


Case Study 4. Compressed Air Driven Hydraulic Power Packs

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Hire Torque Ltd, manufacturer of hydraulic torque wrenches, has a requirement for a compressed air driven power pack to work underground in a coal mine. The power pack had to be built of Aluminum free components. The power pack included a pneumatically operated directional control valve and motor stop/start operated from an operator held pendant.

The power pack, driven by a Globe air motor, delivered a flow of 3 LPM to a maximum pressure of 700 bar. The unit was mounted into a fabricated steel frame with lifting handles and wheels.


Case Study 5. Hydraulic Test System

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Luxfer UK Ltd, a manufacturer of gas cylinders, pressure test cylinders with water to 600 bar. Luxfer were using a compressed air pump to generate the test medium and were finding difficulty in achieving accurate test readings due to the pulsations produced by the compressed air driven pumps.

CFP were asked to offer a solution to the problem and in response designed the intensifier driven by an hydraulic power pack. The result was control of the test pressure to an accuracy of +/-0.25% and a faster, more positive pressurizing of the test piece. Recently we have supplied a test rig (see photograph) with two intensifiers on one caster mounted frame to deliver 350 bar and 800 bar.


Case Study 6. Diesel Driven Power Packs

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The customer, a large Construction and Grouting company in the West Midlands contacted us requesting supply of two diesel driven power packs in enclosures.

For the technically minded. The engines were Hatz three cylinder Silent Packs, the pumps were two Cassappa gear pumps delivering 100 LPM to 60 bar. Each pump provided individual flow and pressure via directional control valves with remote operating levers, to two grouting systems.

The packs had oversized fuel tanks to enable the packs to run for 24 hours per fillup.


Case Study 7. Flow / Pressure Test Rig

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A flow / pressure test rig was built for an American company who manufacture oil well drillheads. The drill heads are state of the art units using hydraulics to control the angle of drill. The test rig provides a flow and pressure to the head so that full operational tests can be carried out after manufacture without the need to drill.

The test rig incorporated an electronic flow meter, electronic pressure gauge, oil temperature controller.

The rig maintains a flow and pressure at content temperature.


Case Study 8. Portable Power Packs

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Five portable power packs were recently supplied to local hydraulic hose company for export to China.

The packs are mounted onto a "wheelbarrow" type sub base with 200 dia wheels for ease of manoeuvring.

The packs are driven by single phase electric motors. A manual control valve, motor starter and supply cable are included.


Case Study 9. Hose Swaging Equipment

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Hose swaging machines were supplied to manufacture of large bore hoses. The machines consist of a 100 tonne capacity ram built into a frame together with the tooling plate. The power pack consists of a totally submerged motor pump set to meet size parameters. The ram controls are by solenoid spool valve operating at 700 bar.

Tooling sets are provided by the manufacturer of the fittings.


Case Study 10. Belle Tout Lighthouse

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In conjunction with Abbey Underpinnings, CFP moved the 160 year old Belle Tout Lighthouse at Beachy Head in March 1999. The 850 tonne lighthouse and its associated buildings were moved back 17 metres from the cliffs using sliding techniques to prevent it falling into the sea due to serious e rosion of the chalk cliffs.

The lighthouse had to be moved smoothly and precisely without fear of structural damage, CFP designed and built the hydraulic rams and power pack incorporating extremely accurate pressure and flow control valves; this ensured the lighthouse was successfully relocated to its new position without the need for major re-construction.

The project received worldwide acclaim and was extensively covered by the media.


Case Study 11. Friction Welder Hydraulic Power Unit

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A major manufacturer of friction welding equipment required an electrically driven power unit to drive a friction welder designed to weld API connections to oil well drill rods and tubes from 5 1/2 inch to 16 inch diameter.

CFP designed and built the unit with two electric CMG motors (11kw and 18kw) and two variable piston pumps with maximum power controls delivering from 30 LPM to 130 LPM, up to a maximum pressure of 200 bar. ATOS digital proportional pressure controls were used due to the required technical specification and capability of these units to ensure the pressure difference was +- 0.25%.

Special purpose valve manifolds were commissioned through Related Fluid Power to suit the
customer's requirements and the complete unit was designed, built, tested and commissioned
within twelve weeks.


Case Study 12. Airbus Wing Moving Project

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Airbus, commissioned CFP, Digitron Translift and King Trailers to develop and build a hydraulically operated trailer to carry, load and unload the completed wings for the A440M onto a specially built A380 to transport the wings from their manufacturing facility at Felton, UK to Toulouse where they would be fitted to the A400M. This unit had to be transported and powered from a standard airplane tug which operates a 24v power supply, whilst having the capability of moving an 8 tonne cargo with total precision and be housed within the physical constraints of the carry trailer.

A custom built pair of ALPATEK 4kw, 24dc electric motors, ATOS proportional valves with electronic drivers and built in adjustable ramp were used to ensure a smooth and precisely controlled acceleration and deceleration of mass from standstill was achieved. LODAR remote wireless controls with a hard wired pendant back up were fitted to ensure the operator had optimal visual clarity during operation.

Working alongside the design team at Digitron CFP Hydraulics produced the complete drive train including all the hydraulic and electrical control systems, a 5:1 reduction gearbox, lay shafts, Cardin shafts, couplings and bearings. The hydraulic packs were then installed to both the loading and unloading units, fully tested and commissioned successfully over a 2 day period at King Trailer depot in market Harborough by the CFP installation team.


Case Study 13. Hydraulic Power Units

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Requirement: Build and testing of ten hydraulic power units; each operating two rams, for a major waste reclamation company. The ten units included cabinet, pump, electric motor, reservoir tank, filters, pressure regulation, control valves, internal piping, instrumentation and spillage collection trays.

The power units are designed to operate a rake back and forth in digester and percolator tanks through two cylinders; one mounted at each end. Each rake has a dedicated hydraulic power unit and pair of hydraulic cylinders per machine. The digester packs are powered by 18.5kw electric motors delivering flow to a potential pressure of 350 bar. Percolator packs are powered by 11kw motors delivering flow of 250 bar. Vorth Turbo internal gear pumps were selected for this project due to their overall efficiency, low noise levels and immense pressure capabilities. The control valves are ATOS DHU series which are rated up to pressures of 350 bar.


Case Study 14. Powerpack & Cylinder Sets

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Requirement: A global manufacturer of metal reclamation equipment required the supply of two types of power pack and cylinder sets. The packs were to be manufactured to work on industrial-scale batch decoating, de lacquering, and drying systems, utilising special flameproof fluids and with 316 stainless steel reservoirs. All valve cartridges had to be chrome 6 free and manufactured specifically for this system, these were sourced from Sun Hydraulics with all required seals being supplied from Viton.

The main task for the packs was to clamp the door of the equipment securely during operation for periods up to three days, whilst being able to operate through a rotation of 200 degrees without losing pressure in the system. This was achieved by utilising bladder accumulators and a pressure switch monitoring the clamp pressure at all times.

The overall dimensions for the packs were L 1,800mm, W 700mm, H 700mm. These obviously had to be custom built pieces of hydraulic equipment and so CFP Hydraulic Systems were contracted to design, build and test the packs prior to shipment to the USA for installation.