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In industry particularly high standards are set

Increase efficiency – reduce costs -  These targets are set daily for industrial managers. We have found solutions which have quick pay-backs and which will give you decided competitive advantages. Rely on our experience and competence – which we have gained over 25 years.

 

Predict wear, ensure quality, avoid stoppages

Every maintenance manager is charged with the task of ensuring a problem-free production – and this of course at as low a cost as possible.
The Ultrasonic SPY is a new diagnostic tool using ultrasound. With it, almost as  if in passing, and in spite of the normal loud background noise, defects can be detected with little or no training. Mechanical, hydraulic, electrical and air/gas systems can be monitored. Wear can be detected at its earliest stage, often in time to take remedial action and so avoid unplanned down-time, or even component replacement. The fact that NASA has two SPYs monitoring the systems in the ISS speaks for itself.

With the standard basic kit, the SPY can detect air or gas leaks at up to 30 metres (with normal factory noise background).  An accessory extends this to up to 100 metres, very applicable in chemical and petrolium plants, and in power stations. An explosion-safe version is also available.

Increase efficiency.

Time is money !  For you too ?  SPY users regularly report that they are saving 80->90% of the previous search and diagnosis time.

A further option for the SPY is “Sound CTRL“, a software system which records the ultrasound from bearings and gears and permits these to be archived, evaluated and compared.  Much simpler than vibration analysis, and much cheaper to implement, it has been found by firms which had tried to implement vibration ana lyis not only to be much easier to use and giving the same quality of condition monitoring, but also to be suitable for use in situations where vibration analysis gave no useful information. At a conference in November 2006, the maintenance manager of a major German company reported that they had been working to implement vibration analysis for 10 years already, “but we have not yet achieved what we had hoped for at the start“.  An investment of several million Euros – wasted.   More information:  www.ultrasonicspy.com

Save up to 30% electricity with the Powerboss Integra.

Sawmills, production lines, everywhere there are constant-speed electric motors which are running permanently or cyclically well under full load.
Until now, most bigger motors have been started  with star-delta starters. While they reduce the start-up peaks somewhat, they still produce  spikes which can be troublesome, and restrict severely the re-start frequency, so that many motors idle for most of the time. The Powerboss soft-start feature allows for starts to be programmed over up to more than 4 minutes. In belt-driven systems, the saving in belt cost alone has frequently repaid the investment inside a year. Similarly, a soft stop is available if required, of reverse current braking.
The original function for which the Powerboss was designed, is to optimise power consumption in motors which are running under their design load, or cyclically.  While running off-load, as for example in metal-working machines while the work-piece is being changed, considerable savings are available. Even more saving is to be had with fly-wheel machines, as in the idle phases the power can be switched off completely. Several other feaures are available, and can be activiated by programme if and as required.

To the powerbosswebsite

Broad-band lubricants for less wear and wasted energy

Few realise the degree to which different greases and oils can impact energy use and wear. But grease is not grease, oil is not oil. This was brought home to Richard Chambers almost as a baby. A great-uncle had developed the formula for a new gear oil, which dominated the world market in the first half of the last century under the product name “Castrol“.

The lubricant programme of Chambers GmbH includes lubricants certified to reduce wear by up to 88% (with obvious consequent reductions in energy requirement too). Even tested with modern 0W30 oil in a German university laboratory, a reduction of 3-8% was achieved compared with the oil alone, which agrees. with the results achieved in practice by truck fleet operators, averaging 6%.

These lubricants, which produce a low-friction coating on all friction surfaces, were studied 1984-1989 by the Cranfield Institute in England. They concluded that the use of PTFE-treating oil was beneficial in every mechanical and hydraulic area. The PTFE used in Chambers' products is high-density PTFE, not to be confused with the low-density versions (such as Teflon) well known for coating frying-pans. Researchers at Cambridge University established that high-density PTFE offered  39% less frictional resistance than the low-density version.

With complex gear trains the saving can be even greater, as in the case of a reduction gear system, 149,5 :1.  Here the torque at the output end was increased by 14%. In a piston compressor driven by a 5.3MW electric motor (in an oil refinery), the power requirement was reduced by >5%.

With the paraffine-crude-based lubricants, re-greasing and oil-change intervals can be significantly increased, while here too the energy consumption is reduced. Costed over one or two years and not just looking at the purchase price per kilo or litre, the higher price for these products becomes of no significance. Total lubrication costs (normally at least 80% labour, less than 20% materials) can be reduced by two-thirds, with further benefits through lower energy requirement and wear reduction. Further, with increasing environmental concern, less-frequent oil changes reduce the costs of disposal of the old oil.

 

Rejuvinating old oil seals.

Who  does not know the horrible drops of oil on the garage floor or on the car park ? And this happens often when old-timers are around. LecWec - for all oil types and all oil systems, rejuvinates dried-out oil seals and makes them flexible again. Thus many expensive and time-consuming repairs can be avoided (even assuming that the seal is still available).


Before the development of shaft seals from polymere rubber, many were made from felt. Here, LecWec cannot help, but Chambers offers, if not always a complete solution, a product which will significantly reduce such oil losses.  "dB Wec", brough into the Chambers' programme primarily to reduce noise in differentials and gearboxes, changes the oil's behaviour such that it is less prone to work its way past such felt seals. 

You found more detail information on the detailpage

Intelligent lighting

for warehouses, production, markets.

Here is the radical answer to lighting costs. In a 1:1 exchange with 400W metal hydride lamps, there is an immediate energy saving of 50%, with 20% more light and 20,000 burning hours, so reducing the maintenance costs too by 66%. By taking advantage of the “intelligence“, a digital daylight compensation and occupancy sensor which can be optionally fitted to each light, savings, for example in warehouses, of up to 80% have been regularly achieved. 

The three basic models all offer options to suite them to various requirements. The range covers mounting heights from 4 to 16 metres and gives a quality of light suitable not just for warehouses, but also for colour-sensitive retail environments and quality control.

With present uncertainties about energy costs (other than that they will continue to rise), the pay-back on re-lamping can be achieved – already at present energy prices - through energy savings alone within 24-30 months. In new projects, the additional cost, compared with installing lighting previously available, is typically repaid within 4-5 months.

Further information on the intelligent-lighting website