News –

Rylock doubles production output by automating new pre-treatment plant with the help of NORD Drivesystems AU

For this project, NORD Drivesystems AU supplied four NORD Helical bevel geared brake motors with incremental encoders for individual positioning feedback to frequency inverters.

NORD Helical bevel geared brake motors, unit designation SK9043.1AXZ-80S/4 BRE10 TF IG11, were located at the top of each tower. The hollow shaft and foot mounted gear case enhanced the simple installation required.

Melbourne , 2014-09-29

Rylock Pty Ltd manufacture high quality aluminium windows for residential homes, expressly for the high end of the market. Rylock concentrates on premium quality aluminium windows, all with a large colour choice and an infinite range of windows which are made to exact customer specification and order. Rylock’s fast turnaround delivery requires a large and regular volume of aluminium extrusions, with emphasis on the highest quality of aluminium and the powder coated surface. For more information regarding Rylock Pty Ltd, and their products, go to www.rylock.com For their new factory located at Cheltenham, Victoria, Rylock’s own engineers designed a new aluminium extrusion pre-treatment plant to suit their proposed increased production output. With the additional extra space offered in the new factory, the engineers created their new pre-treatment plant from a clean sheet design. Emphasis was given to make the structure substantial and long lasting, with a view to future proof Rylock’s future production goals.

Design:
The new pre-treatment plant consists of four large vertical steel towers positioned in a large square pattern, all connected with an overhead structure. Suspended from the overhead structure are two large lifting baskets, which contain the aluminium extrusions. The two lifting baskets are fabricated from stainless steel, and are utilized to dip the aluminium extrusions into cleaning, rinsing and etching tanks, as directed by the process programme. The lifting baskets and their load can weigh as much as 750 kilograms so counterweights are utilized to offset the heavy weight. During the removal from the tanks, the lifting baskets are tilted at 8 to 10 degrees to facilitate draining of all fluids. There are a total of seven tanks, each measuring 7.2 m long x 1 m wide x 1.2 m high, and each containing approximately 4,700 litres. The tanks are made of 316 stainless steel ( for the Hydroflouric acid ) and 304 stainless steel ( for the water rinse ) . The control programme commands four separate 0.75kW frequency inverters, which in turn control the four NORD Helical geared motors positioned at the top of each vertical tower. The electrical cabinet door has a external keypad control for simple operation.

For this project, NORD Drivesystems AU supplied four NORD Helical bevel geared brake motors , unit designation SK9043.1AXZ-80S/4 BRE10 TF IG11, with 279.60:1 ratio. These NORD geared motors were supplied complete with an electromagnetic brake, and an incremental encoder for individual positioning feedback to the frequency inverters . The hollow shaft design and external foot mount gear case provided simplicity to the installation, especially with the height required. These NORD geared motors were selected to complete a high duty cycle and for long life expectancy to help future proof Rylock’s new pre-treatment plant. NORD Helical bevel geared brake motors , unit designation SK9043.1AXZ-80S/4 BRE10 TF IG11, were located at the top of each tower. The hollow shaft and foot mounted gear case enhanced the simple installation required.

Process:
In order to produce aluminium extrusions coated with the highest quality of powder coating for the most discerning of customers, extensive cleaning and preparation of the aluminium surface is required. The seven process tanks are arranged in order of the preparation process: Tank 1 has a mix of Hydroflouric acid and Sulfuric acid for removal of oxide layer on the aluminium extrusions. Tanks 2 and 3 are for water rinsing. Tank 4 has Chromic acid which etches the aluminium and provides the lattice work on the aluminium surface for good powder adhesion. Tanks 5 ( dirty rinse ), 6 ( intermediate rinse ), and 7 ( clean rinse ) are for water rinsing off of all chemicals before the aluminium extrusions are moved to the powder coating line. The first lifting basket is tilted to allow successful draining of the acid solution, before moving on to the first rinsing tank.

Production efficiency gains:
Rylocks’ design engineer, Peter Kennedy, advises that the older manual pre-treatment plant required the attention of one operator for a half day, to both load and manually move the lifting baskets in and out of the tanks. This older system processed a total of only 7-8 baskets per day.
With the new automated pre-treatment plant, the process system loads and processes one full basket every 25 minutes, which effectively doubles Rylock’s production output. The new automated system now frees up the operator to allow him to perform production duties elsewhere in the factory.