ICE Electrical - Experts in Automation for Various Industries

Improving Efficiency and Reducing Costs with Wheel Flushing Automation

The mining industry demands robust and reliable equipment to withstand the harsh conditions of operation. At the heart of this reliability lies the performance of heavy-duty mining trucks. To ensure optimal performance and minimize downtime, rigorous testing and maintenance of critical components like wheels are essential.

ICE was tasked with a significant challenge: to improve the operation and efficiency of a highly automated rear wheel flushing machine cell for Caterpillar in Decatur, Illinois. This machine cell played a crucial role in testing and maintaining the rear wheels of massive mining trucks, including models 777, 785, 793, and 797.

The Challenge:

The initial wheel flushing process proved to be time-consuming, with cycle times exceeding 45 minutes per wheel. This sluggish performance hindered production throughput and significantly impacted Caterpillar's overall manufacturing efficiency. Furthermore, the high warranty costs associated with wheel-related issues presented a substantial financial burden.

The Solution:

ICE founder & engineer Brad Morton embarked on a comprehensive project to optimize the wheel flushing process. Key improvements focused on:

• Hydraulic System Enhancements:
• Upgraded hydraulic filtering systems to minimize contamination and ensure optimal fluid cleanliness.
• Refined hydraulic control systems for smoother and more efficient operation.
• Control System Optimization:
• Modernized the Allen-Bradley SLC500 control system for enhanced performance and responsiveness.
• Implemented Variable Frequency Drives (VFDs) to control the 100HP motor that rotates the massive 100-200 ton truck wheels.
• Temperature Control:
• Improved oil temperature heating and control systems for the two 500-gallon reservoirs to maintain optimal operating conditions.
• Data Acquisition and Analysis:
• Integrated a Pamas particle counter for real-time fluid cleanliness monitoring.
• Developed custom software to communicate with the particle counter via RS232C and issue commands to the Allen-Bradley Visual Basic Card.



The Impact:

These strategic improvements yielded remarkable results:

• Drastic Cycle Time Reduction: Cycle times were significantly reduced from 45 minutes to approximately 15 minutes per wheel, a threefold increase in productivity.
• Enhanced Production Throughput: The accelerated process enabled Caterpillar to increase the production volume of mining trucks.
• Reduced Warranty Costs: By improving wheel performance and reliability through optimized flushing and maintenance, Caterpillar experienced a substantial reduction in warranty claims, saving millions of dollars annually.

Machine Specifications:

• Control System: Allen-Bradley SLC500
• Motor Drive: VFDs controlling a 100HP motor for wheel rotation
• Hydraulic System: 6 hydraulic pumping units with advanced filtration
• Temperature Control: Systems for heating and controlling two 500-gallon reservoirs
• Fluid Monitoring: Pamas Particle counter with RS232C communication and custom software integration

Conclusion:

The successful implementation of the MD4855 Gen I Wheel Flusher project demonstrates ICE's expertise in industrial automation and its commitment to delivering innovative solutions that enhance efficiency, reduce costs, and improve overall operational performance. This project serves as a testament to the power of integrated systems, advanced controls, and data-driven decision-making in optimizing manufacturing processes. 

Industries: Heavy Industrial, Plastics, Water & Wastewater, High-Speed Automation, Oil & Gas Refineries, Automotive, Robotics