Client: Rotary Power, Newcastle, UK
Background: Rotary Power, a market-leading manufacturer of hydraulic pumps and motors based in Newcastle, UK, has been a part of the British Engines group for over 30 years. The company produces a wide range of products for various demanding applications, from pumps and motors with up to 125cm³ displacements for the chemical and processing industries to hydraulic motors used in heavy industry with capacities up to 16,000cm³ displacements. Ensuring the highest quality finish, including the removal of burrs and sharp edges, is crucial to their manufacturing process.
Challenges:
- Time-Consuming Process: Traditional hand-fettling methods took up to 45 minutes per component.
- Inconsistency: Manual deburring led to inconsistent quality and the risk of damaging or scrapping parts.
- Increased Volume and Complexity: Growing product complexity and production volumes exacerbated the inefficiencies of the manual process.
Solution: Rotary Power sought a more efficient and reliable deburring solution. After evaluating several options, including water and chemical deburring methods, they partnered with Ellesco, the UK agent for Iowa Engineered Processes Corp (IEP). Ellesco recommended IEP’s Cascade Deburring and Cleaning System, a patented process combining controlled media flow, liquid cleaning compounds, and high-frequency oscillations to produce burnishing, peening, and shearing actions.
Implementation:
- Cascade System: The Cascade System installed at Rotary Power was the 1300 model, capable of deburring large components weighing up to 0.6 tonnes inclusive of fixture and media.
- Evaluation and Results: During the evaluation process, it was clear that the Cascade System was the right choice. The system reduced processing times from 45 minutes to between 10 and 12 minutes, including washing, loading, and unloading.
- Immediate Impact: The introduction of the Cascade System eliminated the bottleneck caused by manual deburring, significantly increased productivity, and improved quality, with no parts rejected since installation.
Results:
- Reduced Cycle Times: The deburring process now takes between 10 and 12 minutes, with some components processed in as little as 5 minutes.
- Improved Throughput: The ability to load multiple components onto simple fixtures improved component throughput.
- Consistency and Quality: The Cascade System provided consistent, high-quality finishes, eliminating the risk of part damage or rejection.
- Ease of Use: Simple setup and programming, with the option for manual or automated loading using robots. A PLC unit controls the process, with individual elements like deburring, washing, and vibration frequency easily managed and pre-programmed.
Client Testimonial: “During the evaluation process, it became immediately apparent that this was the right process for us,” confirms Steve Holt, Production Manager at Rotary Power. “The machine has had an immediate impact on our business with productivity increasing dramatically, and the previous bottleneck caused by manual deburring has disappeared completely. Quality has also benefited, with not one part being rejected since the machine was installed. We are now confident to issue parts from the Cascade machine directly to assembly. Throughout the evaluation process, the key issues were quality and consistency, the dramatic reduction in cycle times being an added bonus.”
Conclusion: The Cascade Deburring and Cleaning System transformed Rotary Power’s manufacturing process, dramatically reducing deburring times, enhancing product quality, and increasing overall efficiency. By partnering with IEP and implementing the Cascade System, Rotary Power overcame their deburring challenges and achieved significant operational improvements.
