MOMENTUM EDITION 3 MARCH 2022
AHEAD IN THE CHAIN GAME HYDRAULIC GUILLOTINE GATE FOR CRUSHER FEED HOPPER THE REBIRTH OF A ROOF BOLTER
HYDRAULIC TESTING AND MAINTENANCE PROGRAM FOR JBS MEAT PROCESSING NEW TUBE BENDER FOR CRAM
cram.com.au
CRAM operates in highly specialised fields of fluid power, electro-hydraulic engineering & design, undercarriages and specialised maintenance and engineering services. CRAM also acts as a full service provider to facilitate maintenance, refurbishment, repairs and overhauls throughout the entire life cycle of industry equipment and machinery. Our team is compelled to keep machinery moving reliably into the future, fuelled by innovation, dedication and passion for individualised engineering solutions that are driven by customer needs in an ever-changing market.
CONTENTS
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Ahead in the Chain Game
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Hydraulic Guillotine Gate for Crusher Feed Hopper
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The Rebirth of a Roof Bolter
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Hydraulic Testing and Maintenance Program for JBS Meat Processing
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New tube bender for CRAM
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Our Satisfied Customers
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Our Suppliers
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GET IN TOUCH
Ô Visit our website cram.com.au ¼ (02) 4272 4092 º sales@cram.com.au 2
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AHEAD IN THE CHAIN GAME
A bespoke longwall chain tensioner is maximising the operating potential and safety characteristics of the new AFC ribbed chain.
Developed in a collaboration between Motion Australia’s fluid power business unit CRAM and consulting mechanical engineers PHD Engineering the new tensioner has been developed to maintain the integrity and functionality of existing chain tensioning systems while taking the construction of the AFC chain into consideration. The new tensioner is to also improve reliability and efficiency. The AFC chain is structurally different in that it has a steel rib across the middle of each link, which makes it incompatible with existing chain tensioners. The new tensioner is designed to clamp over the chain, rather than the traditional hook-the-link system. Correct tensioning of the longwall chain is vital for the smooth operation and performance of the conveyor. A hydraulic control circuit, operating through dual hydraulic cylinders, initially tensions the conveyor to a start-up force which will avoid any breakaway friction. Once the conveyor is operating to optimum efficiency, the tensioning is reset to a (generally) reduced level of force – a level that allows for normal operation and avoids overstressing any components.
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Profile of AFC chain
At this stage of the design process, and because of their experience in the maintenance and servicing of longwall chain tensioners and particularly the cylinders used on such systems, CRAM was called in. The design of the new chain tensioner would see the level of efficient functionality retained however the new components in the system – to account for the different structure of the chain – would require more robust hydraulic components. Aware of the physical and mechanical design characteristics of the new tensioner, along with the expected start-up and normal operation service load hydraulic pressure demands the system would make on the hydraulic circuit, CRAM’s first step was a more robust cylinder. It had been determined that the system operating pressure would be 450 bar maximum, which would deliver around 28 tonnes of pull force. This level was well within the mine’s requirement of 25 tonnes and would protect the hydraulic components from excessive operational stress and potential failure. Additionally, this level was easily achievable from the hand pump used to prime the system prior to start-up. CRAM completed the entire cylinder manufacture in house and utilised our broad range of suppliers for componentry and raw materials.
In a novel approach, the existing tensioner was reverseengineered, and with the knowledge and data from that step, a more robust cylinder was developed to suit the new connections designed by PHD Engineering. Through the reverse-engineering process, CRAM used the key characteristics – stroke, barrel internal and external diameter, rod diameter and pin-to-pin distance – to develop a design that replicated the existing arrangement but took into the account the structural/ mechanical changes to the tensioner. The design was reviewed and approved prior to manufacture and supply to PHD Engineering for assembly and final testing before installation and commissioning at site. The new tensioner is working to design and specification. At the time of writing it had been fully tested – both for operation and with a 200% proof load - and certified by a NATA-accredited testing authority. The involvement of CRAM is this project has again highlighted the company’s experience in specialist hydraulics. With all design, manufacturing and assembly completed in-house, quality control could be managed and maintained to meet the standards expected by our client.
PULL PULL
Test procedure is to pull chain at each end to 25 tonnes, then engage Hydraulic cylinders to ensure link is loose and can be “wobbled” by hand
PULL
12.5 tonne Hydraulic Cylinder
Link Block
PULL
25 tonne operating load test using hydraulic cylinders
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HYDRAULIC GUILLOTINE GATE FOR CRUSHER FEED HOPPER
Four Motion Australia business units – CMA, CRAM, SMS and CBC - have combined to design, build, install and commission a hydraulic guillotine gate for the ore crushing cycle at one of Australia’s leading iron ore miners.
The gate is designed to shut off the bottom of the feed hopper and prevent any ore from dropping onto the crusher feed belt. It is specialised equipment which ensures the site’s maintenance teams can safely carry out any work necessary. By installing this gate, the maintenance team can isolate a feed hopper and do the maintenance work on the belt feeder and crushers downstream while the rest of the plant keeps operating. The mechanical design work of the gate was completed by a Perth-based consultancy who called in CMA to assist with the hydraulic design for the operation of the equipment. This design collaboration, and a long-term professional relationship with the miner, led to CMA being awarded the full project. The input of the four Motion Australia business units took this project from being a design on paper to ultimately installed and commissioned in an iron ore mine in the Pilbara.
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The gate is designed to shut off the bottom of the feed hopper and prevent any ore from dropping onto the crusher feed belt.
CMA was responsible for the design of the hydraulic system including the HPU (hydraulic power unit), the SMS heavy fabrication workshop at Unanderra manufactured the gate and its infrastructure and CRAM supplied, manufactured and fitted the necessary hydraulic pipework including the fail-safe lockout system. A Perth-based CBC engineer was able to provide technical support at site during commissioning – an important aspect of the project given that a pandemic had meant interstate travel was not possible at the time. Although working to detail drawings the technical expertise and experience within the business units involved allowed for on-the-run improvements to the gate as the job progressed. CMA was able to overcome an issue with the clevis ends on the hydraulic cylinders. The specified pins were sized correctly for their material property however the load rating of the clevis itself hadn’t been taken into account. When this was discovered a quick consultation with the customer, the hydraulic cylinder supplier and the engineering consultants saw the clevis and pin resized to suit the load in the application. A minor change and rework which possibly avoided some unplanned downtime.
SMS engineers found that the weld-on trunnion mounts for the cylinders didn’t leave any room for any adjustment of the mounting points – an important consideration on such a long welded structure as the gate. A new design was proposed – trunnion mounts which would bolt on to the structure and give the flexibility needed. The variation was approved and new mounts quickly manufactured and the project stayed on track The project had a three-month schedule – from paper plan to commissioned gate – however the cooperation and involvement of the business units meant the job was completed on budget and ahead of time. Ironically, the early completion of the fabrication allowed for minor improvements to the finished gate in Perth prior to its final transporting to the mine – improvements that had been identified would improve operation and which will be included in the second gate for the project.
The project included design of the hydraulic system including the HPU (hydraulic power unit).
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THE REBIRTH OF A ROOF BOLTER
The client wanted a new roof and wall bolter. The problem was the delivery lead-time quoted by the manufacturer was well outside the envelope of what the mine’s production schedule deemed feasible. The solution was to get CRAM Mining and Undercarriage to essentially rebirth a machine the client had withdrawn from service.
The Fletcher CHDDR17 is a track-mounted roof and rib or wall bolter used in underground coal mines. Its function is to drill holes in the roof and walls and then install chemically-anchored bolts to stabilise the rock strata. It’s a big machine: it weighs in at 26+ tonnes, is 8 metres long x 3 metres wide and just over 1 metre high and has an operational height range from 1.2 metres up to 5.2 metres.
of weld repairs and re-welds. When repaired, theses parts were painted and stored ready for re-assembly. All pins and bores were evaluated for serviceability then, depending on their condition, either cleaned and reused or removed and replaced.
This is the machine sent to CRAM for a complete overhaul and rebuild.
All the actuators were stripped down, inspected and overhauled – which in this case included re-chroming and grinding of the rods, bringing them back to original specifications. After necessary repairs were made, new seals were fitted to the cylinders then new hoses fitted. The hydraulic pumps were replaced and the valves stripped down and either repaired or replaced as considered necessary.
However the job would prove to be considerably more than a strip down and rebuild. The machine had been languishing in a machinery ‘graveyard’ for almost ten years. No maintenance had been carried out and many of the parts were not serviceable. It would be a back to square one; a nut-and-bolt rebuild. The first step was to strip the bolter to its bare bones, sandblast all metal parts to remove any rust and the like and then test all the structural components for cracking and any weld defects – a step that initiated three weeks
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The hydraulic circuit – vital to the operation of the machine – was completely removed.
All the components were individually tested and then reassembled ready for installation. Two of the sixteen cylinder assemblies on the machine were purchased and fitted to replace the original units
lost over the years of dormancy. On two bespoke cylinders from Fletcher, some technical troubleshooting was necessary, requiring the rams to be replaced new. Ultimately they too were ready for installation as the machine went back together. The electrical circuit was subject to the same process. All components were stripped out and replaced with modern equipment, including the addition of a PLCcontrolled tramming system.
Projects of this nature are a core function of CRAM Mining & Undercarriage and the company brings extensive knowledge and resources to such jobs. The ability to complete almost all tasks in-house gives the company and its clients significant cost and efficiency advantages.
The undercarriage assembly was reduced to its component parts. The tracks frames were stripped, the track guides were replaced on the track frames and new track plates were purchased. Then, following a thorough inspection, the gear train within the track frames was replaced old for new. With the exception of two specialised services – electrics and re-chroming – all the work was completed in-house which ensured consistency of workmanship and quality control.
Valve blocks were remanufactured in house
Logistically the job was not without its challenges – keeping track of 1000+ individual parts occasionally resembling a giant jigsaw puzzle on the workshop floor was achieved through a proven tracking and storage system – but in a little more than 26 weeks the machine had been completely stripped, inspected, repaired, overhauled and rebuilt to original specifications and returned to site for re-commissioning. CRAM Mining then turned its attention to the compliance upgrade of two machines recently acquired by the same client. Although not as detailed as the rebuild, bringing the two machines up to Australian compliance requirements and standards was just as technically demanding. Both the hydraulic system and electrical system required upgrading.
New MDG-compliant hosing
Under Australian compliance conditions, hydraulic hoses are required to be compliant with the relevant Mining Design Guidelines, which meant removing and replacing all the hydraulic hoses on both machines. Additionally, the hydraulic oil had to be replaced which meant flushing the system and replacing it with an approved fluid. While these upgrades to the hydraulic system were under way, the electrical system too was replaced in order to meet the relevant Mining Design Guidelines.
Some design changes were necessary to accommodate locally-sourced equipment
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HYDRAULIC TESTING AND MAINTENANCE PROGRAM FOR JBS MEAT PROCESSING
A call to CRAM from BSC Wagga Wagga has meant specialist repairs and a targeted hydraulic maintenance program to improve equipment performance and reliability.
JBS Meat Processing is one of the world’s largest meat processors with fully-integrated facilities in Australia, South America, the United States and Europe. Around twenty-four months ago one of the feed trucks used to distribute grain to the stock held in the feedlot at the JBS Wagga Wagga processing facility was refurbished. Based on the planned upgrade program – which included a range of mechanical/structural modifications - the site was of the understanding that the truck could carry an additional 150kg of stock feed, therefore improving its efficiency. Since going back into service, JBS has twice replaced the gearbox on the feed distribution system mounted on the rear of the truck. (Power for the feed spreader comes from the truck – a PTO from the truck drives a hydraulic pump which drives the hydraulic motor which, in turn, drives the planetary gearbox. A shaft from the gearbox turns the spreader to distribute the feed).
Each mill has its own powerpack which energises a cylinder to compress the two rollers which regulate the flow and required size of the grain.
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A feedlot to service and stock to maintain means feed storage. The JBS Wagga Wagga facility includes five silos for grain storage, delivering raw grain to five mills for processing into stock feed. Each mill has its own powerpack which energises a cylinder to compress the two rollers which regulate the flow and required size of the grain. Up until the middle of 2019 the powerpacks were serviced on a regular basis by a local hydraulics technician however when he sold his business the
new owner was reluctant to take up the service contract at JBS so the packs have not been serviced for more than thirty months. These two hydraulic-oriented issues prompted JBS to call BSC Wagga Wagga for a resolution. BSC called CRAM. The problem with the gearbox started when the load was increased by 150kg and the customer wanted to know if there was a problem with the hydraulics. Was the additional weight putting too much load on the gearbox?
services available within the group and the many advantages such collaborations can deliver. Our testing regime eliminated the hydraulics as the cause of the gearbox problems and have given a pointer as to what the underlying problem could be. A site-specific maintenance and monitoring program will improve operation of the powerpacks and deliver long term benefits. And our willingness to get involved has enhanced the relationship with our client.
To pinpoint the cause of the gearbox failure – and with a view to providing solution – a series of tests were undertaken specifically to test the hydraulic pressure when the system was under load; in this case distributing the feed. Two trucks were involved in the test: the refurbished truck and a one of the original vehicles. The results were surprising. A comparison of the operating pressures of the gearboxes in the three trucks (the site decided to include all three trucks in the test series) revealed that the gearbox that was giving the problems was the one operating at the lowest pressure (it was running at 3000psi/200bar, one of the other trucks was running at 3200psi/220bar and another at 3400psi/235bar). The series of tests revealed the hydraulics are working as designed however they have unmasked a potential mechanical problem with the alignment of the gearbox to the feed distribution infrastructure. As to the powerpacks, one of the questions JBS asked was could we supply the oil and any necessary parts required to provide the level of service required for these units. We pointed out that not only would we supply any parts and consumables we would also introduce a monitoring program for each powerpack to track its performance. As a unit, powerpacks are not overly difficult to service however their reliability and performance comes from a regular inspection, servicing and monitoring regime. As a first step – and given the two and a half years since the last service - each powerpack was essentially stripped down, thoroughly inspected and re-assembled with new filters, breathers, clogging indicators and any other parts (if required) and new hydraulic oil.
Each powerpack was essentially stripped down, thoroughly inspected and re-assembled with new filters, breathers, clogging indicators and new hydraulic oil.
Step 2 is the condition monitoring program for each powerpack. At the completion of the service an oil sample was taken which will be the reference point for future samples. In six months a second oil sample will be taken and analysed and every six months after that oil samples will be taken. This program will give a good indication as to the condition and performance of the powerpack and also provide an early warning system around potential unit failure. The decision by the BSC Wagga Wagga branch to involve and work with CRAM has highlighted the specialised hydraulic
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NEW TUBE BENDER FOR CRAM
As projects become increasingly complex, technology responds with the equipment and infrastructure to meet customer demands. CRAM has taken delivery of a new CNC tube bender – state-of-the-art technology that will give the company and its customers a discernable edge when it comes to meeting the growing demand for specialised hydraulic installations. The new YLM CNC tube bender uses proprietary 3D simulation software to preview and determine interferences and maximise productivity. The same software means the control system can import XYZ axis information from .dxf or STEP files and translate this information to a production schedule.
Hydraulic valves and integrated circuits control the bending motion and the bender is equipped with a manually adjusted digital flow regulation valve to control the speed of the bending action. Combined with the machine’s 4/5 axes servo drive for high accuracy, the outcome is high quality bending.
The industry-leading bending technology inherent in the new machine delivers some impressive performance characteristics. Maximum tube OD that can be bent is 50mm with a wall thickness of 2.5mm. Maximum bending angle is 190° with a bending radius of 2x diameter, although this radius can be altered to suit customers’ requirements using different formers.
It has the ability to perform complicated and repetitive work, quickly and accurately. Once all bend parameters have been entered and verified through the simulation software, the machine is essentially set and forget until that particular job is completed. All parameters for all jobs are stored and can be recalled at any time.
Tubes up to 5 metres can be accommodated on the feed rail. The maximum working distance of the mandrel – which allows tubes to be bent into smooth curves without undesirable creasing, kinking or collapsing – is 2.5 metres.
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The new tube bender and the recently installed EO2FORM tube-end former will combine to give CRAM an industry leading tube fabrication capability. A faster and ultimately cheaper method of connecting tube and fittings, the EO2-FORM is designed to eliminate leakage in all fluid systems by using elastomeric sealing
systems. The cold-forming process gives extreme rigidity and low tightening torques and eliminates any special tube treatment, heating or chemical additives which have been used previously. This high efficiency pipe bender and the unique EO2 tube-end former are valuable additions to the CRAM equipment register and will exponentially expand the range of service we can offer clients. Their minimum waste – maximum productivity operating systems minimise costs - another benefit for customers across the industrial spectrum.
All bend parameters have been entered and verified through the simulation software
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OUR SATISFIED CUSTOMERS Over the last 25 years, CRAM have serviced hundreds of customers in various capacities across a wide range of industries. in-house.
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Mining Industrial Manufacturing Agriculture Energy Minerals Transport
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Construction Waste Management Materials Production Infrastructure
ACCREDITATIONS CRAM’s management systems are certified to ISO 9001 Quality Management Systems, ISO 45001-2018 Occupational Health and Safety Management Systems and accreditation to AS/ NZS ISO/ IEC 17020 general criteria for the operation of various types of bodies performing inspections. The aim is to provide a comprehensive set of concepts and tools for the leadership and operation of a continuously improving organisation with a major focus on customer needs and the expectations of all stakeholder
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Certification to ISO 9001 & AS/NZS 4801
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Accreditation to ISO/IEC 17020
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Compliance to ISO 14001 Environmental Management
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Zero Harm to the environment
ISO 45001-2018
OUR SUPPLIERS CRAM has business partnerships with an extensive range of world class suppliers and quality products.
ELECTRONICS AND CONTROLLERS
PNEUMATICS
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LOCATIONS NSW UNANDERRA HEAD OFFICE 14 Glastonbury Unanderra, NSW 2526 (02) 4272 4092
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cram.com.au | h Ph: (02) 4272 4092
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