According to Dr. Ernest Rabinowicz of the Massachusetts Institute of Technology (MIT), 70% of moving machine failure is the result of wear and corrosion. Both of these factors are due to ineffective lubrication. He goes on to state that 6% of GDP is lost through mechanical wear.

Who would have thought that over $1 trillion could be the size of the prize if we, as a nation, could combat this problem? If you worry about machine failure, read on to learn about the benefits of lubrication.

Machine Failure

When machine failures occur, investigations reveal causes such as contamination, misalignment, installation error or overheating. There is often a lubrication cause to these explanations.

The four features of good lubrication practice are:

• Correct lubricant
• Stable lubricant
• Contamination control
• Sufficient and sustained lubrication

Maintaining these good lubrication practices reduces the causes of a breakdown.

How Does Lubrication Reduce Wear?

When two objects are in contact, the force that resists relative motion is friction. Friction is useful in many ways, but there are times when it is not. Friction generates heat in bearings, heat results in expansion and expansion can result in bearings seizing.

Lubricating machinery minimizes the friction and the resultant heat. Any heat produced is then transferred to the lubricant and removed by a lube cooler. Friction and heat are not the only things lubrication reduces.

When two materials rub against each other, tiny imperfections in their surfaces rub and fragments break off. These fragments act as an abrasive resulting in more surface damage. A lubricant protects both surfaces.

Some lubricants contain additives. They attract contaminants such as particles worn from the surfaces in contact. These can then be filtered and the contaminants removed before they can do any damage.

How Does Lubrication Reduce Corrosion?

Many machines operate in situations where there is some level of humidity. When metal and air come into contact with water, the result is corrosion. Corrosion is one cause of machine failure.

Specific lubricants have additives which prevent rust. They do this by protecting the metal from coming into contact with moisture. Without rust, the metal surfaces remain sound, and the machine is less likely to fail.

Lubricating For Machine Longevity

Lubrication extends the life of machinery by reducing heat, friction, wear, and corrosion but this is only successful if the lubrication regime is fit for purpose. The right lubricant has to be in good condition and uncontaminated. It must be applied in sufficient quantity and at the right level of frequency.

Failing to adopt this standard means optimum machine life will not be achieved. Machinery manufacturers often guide the lubrication needs of their machinery. These should be followed.

The International Council for Machine Lubrication is an independent organization established to develop machine lubrication as a technical field. It provides certification for skills in machine monitoring, lubrication, as well as oil analysis. The proper application of standards in lubrication must pay dividends in reducing equipment downtime and machine failure.

To talk to someone about your machinery needs, contact us.

Often overlooked, a cylinder clamp performs a vital role in all types of industrial-based machinery.

Let’s take a moment to explore how they work and why their performance can be directly tied to the effectiveness and safety of a machine.

What is a Cylinder Clamp

It’s always good to start with the basics. Cylinder clamps provide a precision force to hydraulic, pneumatic, and electrical systems.

In short, their function is to maintain the power that keeps a system in motion. When they malfunction, it can cause an erratic system behavior or even a stoppage. This holds not just production issues but also safety concerns, both of which are good reasons to perform preventative maintenance on each cylinder clamp within a system.

These clamps also work to maintain the stability of a system. When placed correctly, they can keep the extra movement in a system down and guard against quick shifts in the positioning of a pipe due to inevitable pressure surges.

System Check

Some preventative maintenance measures can be performed while a system is running. For instance, have you noticed a change in the machine output? Is there anything to indicate that it’s not running at capacity?

A visual inspection is also important, both of the cylinder clamp itself and the surrounding area. Do you notice any blemishes, rust, cracks, or other marks that might indicate the start of an issue?

Do you also see any displacement of oil, feel the excess air, or detect any pooling of hydraulic fluid that might indicate the equipment is not performing as needed.

Repair vs. Replacement

If you notice any areas of concern that a repair may not overcome, it might be time to look at a replacement. There are some variations of cylinder clamps that you could consider changing to.

Before making a decision though, make sure to do your research to ensure that changing clamps will not void the warranty of the machine or cause potential compatibility (and safety) issues.

Rod Locking Cylinders

One replacement option can be found in rod locking cylinders. These have been specifically designed to lock into place should the system fail.

So, if there is an issue that causes a loss of hydraulic pressure, the machine will not continue to operate or stop hard but essentially freeze in place. This can help prevent damage to the machine overall and, more importantly, could head off serious injury caused by a misfiring machine.

While a rod locking cylinder can add a safety component to your equipment, it’s important to note that it is not intended to be a replacement device for your entire safety system.

Next Steps

We just took a brief look at what a cylinder clamp does. If you have one machine or hundreds working for you, you’re bound to rely on this part to keep your operation running smoothly, efficiently, and safely.

We’d love to talk with you in more detail about how you can keep this key piece of machinery from causing you headaches and downtime.

If you’ve ever been guilty of not properly maintaining your equipment, you’re not alone. Many field experience industry-wide cultures that prevent regular preventative maintenance from taking place.

Unfortunately, this can lead to many problems with your machines and equipment.

Keep reading to learn why a preventative maintenance schedule is an absolute must for all of your company’s gear.

Extending the Life of Your Machinery

Setting up and following a preventative maintenance schedule can help to extend the life of your machinery.

Most types of heavy machinery require oiling and fine tuning to stay running.

Failing to perform regular maintenance could cause your machinery to stop operating correctly. It could slow down your equipment, or even cause it to stop working entirely.

But with regular maintenance, you can extend the life of your machines by keeping them running the way that they should for longer.

Preventing Costly Repairs

Without regular maintenance, your machines’ moving parts will eventually degrade. When this occurs, it is likely that your cranes and other machinery will need costly repairs or parts replacements to get back to running order.

Regular maintenance helps to reduce the need for these types of repairs. You will spend money on regular maintenance. But you are saving money compared to replacing parts or rebuilding broken machinery.

Knowing When an Issue Arises

Even with regular maintenance, normal wear and tear will occur on all heavy machinery.

But when you follow a preventative maintenance schedule, you’ll be more likely to know when these types of repairs will be needed.

An experienced repairman will be able to judge how quickly parts are wearing. With an estimate of when more extensive repairs or parts replacements will be needed, you can better plan ahead.

This could mean planning to get temporary equipment. Or otherwise preparing for the disruption to your normal workday. It also means having the ability to somewhat plan for the cost of repairs.

For small businesses, unexpected repair costs can put a serious dent in the flow of operations. The ability to plan and save money for those repairs can be a lifesaver.

Finding replacement parts can also slow operations. Being able to plan ahead can allow you to source difficult to find parts and to help reduce how much downtime your equipment has while it is undergoing repairs.

Meeting the Demands of a Warranty

If your equipment or machinery has a warranty, it usually requires that the machine or equipment undergoes regular maintenance.

Failing to do so could cause you to violate the warranty. When the time comes that you want to put the warranty to use, you might be denied your claim if you can’t prove that the equipment was maintained properly.

Setting a Preventative Maintenance Schedule

Setting up a schedule for regular preventative care can save you loads.

If you’ve recently bought a new piece of equipment and aren’t sure what kind of maintenance is needed, or if you need a replacement part to keep your gear running, contact us today.

The productivity of your business depends on the well-being of your equipment. Any downtime due to machine failure can be devastating. Business operations become out of whack disrupting service, staff comfort, and customer relations. Not to mention that the safety and health of your workers are put at risk.

Equipment breakdown is very costly. You only have two options: repair or replace, and both can be expensive. When the motor needs replacement, you’ll have to pay labor costs for removal, costs for installment, and freight costs.

Recognizing problems with the important parts, such as the brake pads and rotors, is key to preventing machine failure. What are the things to look out for? Read on to find out.

Rattling and Squeaking, Clanking and Squealing

When you’re driving your car, you love the purring sound the engine makes. But when you hear an unusual sound, you know that it’s time to open the hood and see if anything’s wrong.

Your employees are also familiar with the normal sounds of the machine they’re working on. When they hear an abnormal sound, that is usually one of the signs of imminent failure.

Just like your car, an unfamiliar noise warrants an immediate inspection.

Worn out Brake Pads and Rotors

Machine failure is usually caused by parts showing their age. Using our eyes to look for signs of wear is part of preventative maintenance.

Examine the belt, bolts, and other important parts of your machine. Does your belt have cracks, abrasions, or fraying? Are the brake pads and rotors starting to warp or showing gouges? Are the bolts out of shape or loose?

Replacing aging parts is cheaper than replacing the equipment itself. Before machine failure happens, change the worn parts with new ones.

Slumps in the Efficiency

A decrease in production speed affects your bottom line. But more importantly, it signals that the machine is starting to break down. And when it eventually fails because you neglected the warning signs, you’re going to lose a great deal more.

A slowdown in production usually indicates resistance in the machine. This could be due to lubricant leakage or due to damaged parts causing friction.

Speaking of friction, another byproduct of inefficiency is unexplained heat. Of course, heat is normally created as the machine works. However, when heat is produced in areas that should be cool, that is a problem.

Another hint of impending machine doom is when the temperature shoots up higher than normal. You should also suspect electrical failures for unexplained heat.

Address these issues immediately, or the heat could lead to a fire.

Dirty Machine

A clean machine runs smoothly. Dust and debris clog up the important parts and can cause the machine to seize.

Filters keep the dirt off of your equipment but must be routinely changed. Seals, when damaged, can’t perform their protective duties. When seals are compromised, you’ll spot leaks and wetness in areas where you don’t find them under normal conditions.

You should schedule a regular inspection of the important parts. Repair or replace them when necessary.

An Ounce of Prevention

Your production equipment is critical to your business. Once you recognize these warning signs, preventing further problems from happening will save you money in the long run.

Request a quote for our equipment repair services right now.

Everything you look at only fills half your needs. You’ve got a tight budget and tighter timetable. Nothing quite fits.

Does this sound like you? While a stock piece is standardized and available almost immediately, a custom fabrication can meet 100% of your needs.

Custom fabrications have increased useful life since they can be customized to the environment and particular wear pattern. Backward compatible for machinery no longer in production, non-standard processes? No problem.

Are you sure that custom fabrication is what your business needs? Then you need to choose the right company to make what you need. Here’s the breakdown of what to look for in the right custom machine shop.

What’s Their Experience?

You want someone who can execute your ideas or reverse-engineer a worn piece. For that, you need someone with practical experience in your field, whether it is an oil-rig or hospital. There isn’t a field manual for pieces that don’t exist in catalogs.

Experienced metal fabricators know their materials and techniques. They can recommend solutions and handle customization with efficiency. More experience means fewer errors.

Check Their Work

Get to know the quality of a company’s work by checking out their portfolio. Talk to past customers and view past projects. You want to know about the durability and quality of their custom fabrication.

What is their safety record and how do they handle remanufacturing critical parts? It will also give you an idea of how they handle the specs of individual designs and their capacity for large or small size jobs.

Capacity for Work

Can your fabricator build in the material you need? What kind of machinery do they use? For high-quality steel welds that lives depend on, no one wants to see a 90 amp Home Depot special! The right tools and technique can mean lives.

Location is relevant. Consider fuel costs and control over your fabrication. Will you be able to communicate with your machine shop? How quickly can your shop turnaround? Will time and distance affect your costs?

Get to Know the People

You want a long-term relationship with your company. Each project is unique and your business is like no other. You want a metal fabricator who recognizes that!

Compare Quotes For Custom Fabrication

Of course, you have to follow procedures and get quotes from many shops. For the best possible outcome, you want a custom fabrication shop that can give you what you need, at a reasonable price, and on your timeline.

Take the time to get to know your vendor and their capabilities before deciding on price alone.

For more interesting and informative articles, keep reading our blog. If you want to know more about the most qualified and experienced metal machining and fabrication shop, contact your Kor-Pak representative today.