Product category:
Tugs, tractors, trucks, pushers, jacks, trollies, skips, etc.
News Release from: Brauer | Subject: Wheel change service on materials handling cars
Edited by the Manufacturingtalk Editorial
Team on 09 February 2004
Kiln cars' wheels changed without
disruption
A handling equipment supplier has almost completed the replacement of 600 wheels on 50 brick kiln cars in a staged operation under a two year project without interrupting brick-making.
Thebrickbusiness is the UK's leading independent brickmaker, with a history of brickmaking stretching back 130 years So, when it was time to refurbish kiln cars at its Warnham factory, the company knew that it was looking for something special - a supplier with products that would withstand the aggressive industrial environment of a brick kiln, supported by the engineering expertise that could provide creative and innovative solutions to unusual problems
This article was originally published on Manufacturingtalk on 10 Dec 2003 at 8.00am (UK)
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In HMC Brauer, thebrickbusiness found just such a partner.
HMC Brauer provides manufacturers in the UK and across the world with a range of superior engineered products including clamps, linear bearings, and heavy-duty wheel and castor assemblies -it was this latter range that was of interest to thebrickbusiness.
Naturally, with a 24/7 operation, producing up to 55 million bricks each year, the replacement of a total of 600 wheels on 50 brick kiln cars had to be undertaken as a staged operation and the two year project is now almost complete.
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A simple two step workholding process using a sub-plate installed onto a machine table quickly, accurately and repeatably positions workpieces - giving time savings and increased productivity.
One hand grips, the other is always free
Using pliers that have the novel advantage of being operated with one hand and operator always has one hand available to hold, adjust or handle the work piece.
The brick kiln cars run on four rails through a hydro-casing tunnel kiln, each car carrying 55 tonnes of bricks runs on 12 wheels, running in a water-sand bed - quite a challenge - but one which the Brauer wheels have completely satisfied.
While this initial project was underway, one of thebrickbusiness' Works Managers, Sean O'Dell, mentioned to Brauer that the factory was facing another issue, which, although it only affected four wheels on one transfer car, was nevertheless resulting in production losses totaling as much as 1.5 hours per day.
The affected vehicle was the dryer transfer car, which carries stillages of wet bricks into a series of drying chambers where they are dried at 200degC for 22 hours.
Because the environment is so harsh, this process is entirely unmanned and the car is laser-guided along the 100m twin rails that leads to each of the drying chambers.
The original wheels had flat treads and it was not unusual for the heavily loaded car to slew completely off the track, causing the whole system to come to a standstill as the computer lost connection with the laser guidance system, which then took several hours to re-install.
Brauer proposed a solution that was at once simple and effective.
Two of the original flat-tread wheels on one side of the car were replaced with flanged wheels, thus ensuring that the car stayed on the track.
O'Dell comments; "We are delighted with the modification, it has improved our plant efficiencies and unit costs, it worked immediately, and it has improved customer service - our primary concern at all times.
We are already looking to make further changes to other heavy-duty vehicles in the factory using Brauer wheels and castors.".
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