Industry Partners Albania
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High Voltage Magnetiser
This first time client in the UK reached out to us regarding a non operational high-voltage magnetiser. This machine creates permanent magnets by generating a strong magnetic field that surrounds the working part, orienting arbitrarily aligned magnetic elements into a meaningful field. It was 1 of 2 units which they owned, and had been out of service for over a year. 3 previous attempts at repair by their in-house engineers had been unsuccessful.
Upon inspection, it was clear that the unit had suffered from a large current overflow which had damaged many components in the 24V control cabinet. In prior attempts to repair the damage, wires had been incorrectly connected, damaged components were overlooked, and poor soldering had created short circuits, amplifying the problem. Matters were complicated further by the lack of wiring schematics.
Our engineers tackled this problem methodically, testing power supplies, GPIO, relays and connections, creating schematics for the client as they progressed. Connections were rewired, GPIO's rectified and damaged components replaced. The DC stepper motor was also damaged from the initial overcurrent. A replacement was sourced and installed. After 4 working days, the machine was once more fully operational.
A look inside the high voltage cabinet
The control cabinet as we found it
At this point, we were asked to make changes to the controller logic and reduce cycle time. The original code was provided, and adjustments were made to include a calibration state, ensuring clamping plates travelled a minimal distance, increasing efficiency. After testing the new controller logic, the cycle time was measured. From 42 seconds, the time was reduced to 26 seconds, a 38% gain in productivity.
Needless to say, our client was pleased. This machine was an integral part of his production line, and had been a bottleneck for some time. Over 1 year out of operation, assuming a 40 hour work week, and a conservative 40% usage rate, this was over 800 hours of machine downtime. At a rate of 60 magnets per hour (before our adjustments), this equates to an opportunity cost of almost 50,000 magnets. With our efficiency improvements, this is closer to 70,000.
Control cabinet after work was finished
An example of poor wiring found on the breakout boards
This case highlights the importance of not only finding the right people for the job, but also swift action. A huge loss in revenue from integral machine downtime, our engineers managed to get things up and running in a timely fashion.
If you have a machine that is out of action, or not performing as you would like, contact us by filling out the form below. Our engineers will be happy to discuss your problems, and can arrange an initial site visit free of charge. We believe in open and clear communication with customers, which is much easier when done face to face.