Security Gate System Retrofit
Problem:
A newly installed (by manufacturer) hydraulic security gate system (7 gate locations) was experiencing repeated failures (2-3 day duty cycle), creating terrible traffic backups. The manufacturer’s and the customer’s relationship was terminated. The customer was left with a multimillion dollar system that was not dependable and the existing bill of materials contained substitute part numbers that made component procurement very difficult and very expensive.
Process:
- An exhaustive study of the application was done. Including all component specifications.
- The equipment was observed in operation and production and maintenance personnel were consulted as correct operation sequence functions were determined.
- A course of action which included:
- Identification of failed components
- Upgrade in filtration
- Upgrade of hydraulic cylinders.
- Circuit redesign.
- Creation of a complete hydraulic schematic, including a bill of material containing full manufacturer information and complete model codes.
- Maintenance and production personnel were trained in the function, proper maintenance and troubleshooting procedures of all components.
Results:
- Duty cycle was increased to over 2 years.
- Potential component replacement costs were reduced by over 60%.