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Deborah Hays
Dmax Ltd.
ABSTRACT
The predictive technology team at DMAX, Ltd. consists of a mechanical technician and an electrical
technician. We primarily use the IR camera to run predictive routes on electrical panels, buss plugs, and
motors. Occasionally, we are called to the plant floor to help troubleshoot a problem. This paper discusses a
trouble call on a hydraulic system that supports one of our larger machines.
INTRODUCTION
DMAX, Ltd. builds the Duramax Diesel engine for use in General Motors heavy duty trucks. At our facility the
engine block, head, crank, and connecting rod are machined. These parts are used in our assembly area
where we build and test the engine. The problem occurred on a cylinder block line transfer machine that is
54 x 30 consisting of 5 cutting stations, 2 rotate stations, a gage station, check station and 5 idle stations.
Most of the cutting stations have a left and right side. Each cutting station either bores, chamfers, or mills the
cylinder block. After each station finishes a cycle, the machine then transfers the cylinder block to the next
station. Hydraulic cylinders are used to transfer the blocks as well as rotate them and clamp the part when it
is being machined. Hydraulic cylinders are also used in several stations to assist the large cutting heads as
they rise and lower. This hydraulic system has a 600 liter reservoir of hydraulic fluid. The OEM has stated
that the maximum system temperature should be no higher than 120F (49C) when running at a normal
pressure of 1200 psig. The system has a high temperature fault that is set at 117F (47C). The OEM used
yellow zinc dichromate heavy walled steel tubing to distribute the hydraulic fluid to the desired components on
the machine. There are several supply and return lines running to each station as well as to the large
cylinders used to transfer the blocks as they are machined.
PROBLEM
Electricians from the cylinder block line had been called to this operation numerous times to reset high
temperature faults on the hydraulic system. The electricians asked the mechanics to check the system for
any abnormalities. All pressures and flows were found to be within OEM specification. The electricians also
wanted to verify that the actual temperature in the hydraulic system matched the thermal couple reading. We
checked the temperature using our FLIR P65 and determined that the thermal couples where operating
correctly (Fig. 1). The electricians did not want to spend their day resetting temperature faults. We needed a
solution.
TEMPORARY FIX
The electricians were advised not to adjust the temperature upper limit to eliminate the fault. Running the
hydraulic unit with excessive heat would cause the hydraulic oil to deteriorate at a rapid rate possibly causing
failures to the hydraulic pump, cylinders or valves. The machine was needed to meet production schedules
so there was little time for a formal root cause analysis. We needed a quick solution or what we like to call a
band-aid (Fig 2.).
Figure 2. The fastest and easiest way to cool something down, THE FAN!
REFLECTIVITY
Object Parameter
Emissivity
Object Distance
Reflected Temperature
Label
Sp1
Sp2
Sp3
Sp4
Dt1: [ana.Sp1.temp] [ana.Sp2.temp]
Dt2: [ana.Sp3.temp] [ana.Sp4.temp]
Value
0.96
1.9 m
22.4 C
Value
36.9 C
33.1 C
35.0 C
31.8 C
3.7 C
3.3 C
RESULTS
Twelve cans of flat white spray paint and a week later, we reshot the hydraulic unit. The overall system
temperature went from 117F to 107F. We were able to reduce system temperature by 10F, which was
enough to keep the unit running even on the hottest days (Fig. 5).
SUMMARY
After a week of painting, we realized this operation had several more feet of hydraulic tubing than we had first
realized. We believe this is why we were able to achieve a ten degree temperature reduction. We have since
changed the new equipment specification and require any future purchases of hydraulic systems to have the
hydraulic lines painted flat white. Ten degrees F may not sound like much, but sometimes it is just enough.
REFERENCES
Voitl, John C.; Predictive Maintenance Technician; Coors Brewing Company; 2004 InfraMation Conference;
October 2004
ACKNOWLEDGEMENTS
The authors wish to thank the Infrared Training Center and specifically instructors Bernie Lyon and Bob
Rogers. We would also like to thank DMAX Ltd. maintenance personnel and management for allowing us to
experiment with this operation.
ABOUT THE AUTHOR
Deborah Hays is a Level II Thermographer and has been a mechanical service technician for the last 15
years. She has been assigned as a predictive technologies technician for the past 5 years. She utilizes
infrared, vibration analysis, motor circuit analysis, and ultrasound technologies at her plant.