Rebuilding a machine is a fantastic way to preserve life in an expensive piece of equipment. Often, a machine is disposed of long before it needs to be, due to workers not being aware of nor having the experience and expertise in rebuilding it. This means that thousands of dollars are spent each year purchasing new equipment, instead of simply rebuilding an older model. There are certain steps that must be taken when rebuilding a piece of equipment, as well as an expert mechanic to complete the process.
It cannot be underestimated: a quality machine rebuild is a lot of work. It requires knowledge in a number of different areas, so there might be multiple people involved in the process. These areas include mechanical, hydraulic, electrical, control, and coolant systems to just name a few. There will be multiple steps, from inspecting the machinery to cleaning it, disassembling, as well as repairing and replacing any parts before the final rebuild. However, as complicated as it might seem, there are definite basic steps that all rebuilds will have to go through.
At HDD Solutions, we understand the mining process well and are experts at providing a reliable, professional equipment solution for our mining clients in the Wangara region. This blog will be about the basics of a quality machine rebuild.
The Disassembly
The disassembly will likely be the first part of the rebuild process, once you have decided that this is the route that you will take with the machine. Any machine that needs to be rebuilt should be completely disassembled into its separate parts. From this, you can assess what needs to be replaced and repaired, as well as thoroughly clean all elements before the rebuild process. The parts should be cleaned so as to prepare for any painting that will take place later in the rebuild.
In order to speed up the rebuild process, you can take photos of each phase of the disassembly. This will help you understand what needs to go where so that you don’t rebuild it incorrectly. You can also understand what parts are missing, and replace them easier.
The Mechanical
The mechanical part of the rebuild is arguably the most complex, as it involves many different subparts that will require expert attention, experience, and knowledge. We will go on to explain some of the more complicated elements in this next section of the blog so that you understand everything that it entails. Read on to find out more:
- Guideways: this is an important aspect of the rebuild that involves highly skilled mechanics. There can be different processes for refinishing the guideways which depend on the machine construction. These include cast iron guideways, hardened guideways, ground guideways, rolling guideways, and linear guideways.
- Lead Screws: these screws help the machine move, so it’s vital that they are in the best condition possible. There are two basic types that make up a machine: the acme screw and the ball screw. The age of the machine will determine the type of screw that is in use and therefore need to be removed, inspected, and possibly replaced.
- Wear Parts: you’ll need to replace all wear parts in a machine rebuild. There are certain items that will have suffered wear and tear during the period of time that a machine has been in use, like bearings, wipers, bushings, and seals. You’ll be able to determine what these items are when disassembling the machine, before ordering the new parts and replacing them successfully.
- Gears: Gears need to have special attention applied to them as they are constantly in use while the machine is operating and therefore likely have suffered wear and tear. In order for your machine to work properly once it has been rebuilt, you’ll need to ensure that the gears are all working correctly and in proper alignment with each other.
The Alignment
The alignment of a machine is important to get right. Thankfully, most machines have a specific design that is set according to an applicable standard, meaning that during the rebuild process, you can follow this alignment and ensure it is correct. If the alignment of the machine isn’t quite right, the equipment either won’t work or will not be at its fullest potential when it is in use.
The Electrical
The electrical part of the rebuild is not only important to get right in order for the machine to work as it should, but also to ensure the safety of the operator, too. In order to get this element of the rebuild right, you can look into the proper control system architecture. Remember, these machines are complicated and huge pieces of equipment, that will need an expert in order to rebuild them. Once you have found the correct and safe architecture to follow for your electrical rebuild, we would suggest that a CAD system is an optimal way to design your new electrical design. This should include a thorough design, with identification numbers for devices, colours, sizes, stock lists, and wire numbers.
General Controls
Once you get to this part of a rebuild, you can now consider what controls you’d like for your machinery. If you were unhappy with the set you had before, you can change manufacturer if needed. Make sure to get the right type for your machine and shop around for a price that works for your company. It’s important that when you do a rebuild you don’t go over budget sourcing new and expensive items – this is a great way to save money by avoiding having to purchase a whole new piece of machinery. So, make sure to find the best prices possible for any replacement parts you may need.
Software
This is a highly technical part of the machine rebuild and shouldn’t be underestimated. It’s how the equipment will work and function and should have an expert perform any replacement or different code needed. It’s important to hire an expert for this part as software architecture is a highly technical and complicated process. There are two main types: PLC Software and CNC Software. We’ll go on to explain a little bit more about them here:
- PLC software is used to control the machine’s functions. It requires a highly experienced engineer to completely write a new PLC software for a machine.
- CNC software is how the operator enters program data, which is then turned into proper motions on the machine.
Documentation
This should be the final part of the rebuild process. It is vital that the proper care and attention are dedicated to this, as any future services on the machinery will depend on this documentation. Important elements to include are:
- The CNC manual
- The PLC manual
- The machine operating manual
- The programming manual
- Electrical schematics
- Diagrams and drawings
- All necessary manuals
- A software backup
A machine rebuild is a complicated process. It should be carried out solely by experts, and it will definitely require a team of people rather than one person. However, while it might seem overwhelming and complicated, it is much more cost-effective than purchasing an entirely new piece of equipment. If there is any chance that your machine can be rebuilt instead of being disposed of, we thoroughly recommend pursuing the option.
HDDSOL provides equipment solutions to mining companies across the Wangara region and beyond. As part of our wet-hire services, we are able to provide expert maintenance on equipment that’s used by the companies we partner with. Get in touch today if your company would like to partner with us on our maintenance services.