Every hydraulic press type requires attentiveness, from hand-operated h-frames to more innovative solutions. Leaks, pressure changes and pump handle drifts are only a few notable problems, and manufacturing experts must know how to maintain these critical machines. Here is the best advice professionals have for troubleshooting and repairing hydraulic presses efficiently.
Invest in Training
Organizations lengthen a hydraulic press’s life as operators grow more proficient. Knowing the most up-to-date handling and safety practices ensures stampers do not extend the machine past its limits.
Classes provide hands-on training, including repeatedly reseating check balls and testing defective gauges. Operators also become more familiar with how presses feel when hydraulic drift starts because it changes how smooth and balanced they seem. Continued education prevents unnecessary damage and encourages a safety-forward working environment.
Stampers will also need to know how to use digital transformation technologies. These include control dashboards monitoring the system’s health and parts. Knowing where to locate information can determine maintenance times, so they can be scheduled during nonpeak hours.
Institute a Fluid Analysis Program
Many problems surface from changes in fluid activity. Contaminants enter, viscosity degrades and leaks appear. Mandating quarterly inspections should be the minimum requirement to catch concerns before they become problems.
Operators can filter and change fluids as needed during each analysis using a proactive instead of reactive approach to press maintenance. Organizations will see the benefits in the long term as clean fluids increase the longevity of valves, cylinders and other components.
Perform Daily Visual Checks
Daily inspections force technicians to become intimately familiar with their machinery. It attunes them to identify potential problems sooner, including damage around fittings or hose cracks. Eventually, they will notice when a loose bolt in the tooling area needs tightening or when guided platens need to be regreased.
An operator may find liquid dripping from the piston oil seal, indicating a too-full reservoir or damaged piston packing. Inspections take less time with practice as workers become more proficient at identifying issues.
Experts can also listen to the press as they inspect it, noticing any odd noises that could indicate valve compromises or pump cavitation. These signals could lead to catastrophic incidents if ignored, making the daily investment readily justifiable.
Have a Stock of Spare Parts
Parts acquisition can be an unnecessarily long stage of the repair process, especially as supply chains continue to experience delays. Workers can minimize downtime by having a reasonable stock of critical parts. It is important to have components that wear down easily, like filters, seals and hoses.
They can also have a few additional options for potential upgrades. Components like custom pipe fittings and electronic position devices are crucial for enhancing the production capabilities of an older press.
Reducing breakdowns and production losses is vital for supporting morale, maintaining profits and solidifying reputations. The reserve supplies provide peace of mind for stakeholders and floor workers alike.
Some companies are leveraging artificial intelligence to order parts for hydraulic machinery automatically. For example, if a part is at 50% of its lifespan, the system can notify the purchasing team to order it before total failure. It allows workers to get as much as 90% of a part’s usefulness by having these insights.
Keep Detailed Maintenance Records
Everyone who uses and maintains the press must log their activity. It holds the workforce accountable for interacting with and influencing the machine. The details also inform operators in different shifts if there were unresolved problems, fluid changes, parts replacements and other notable activities that could alter workflow.
The notes will also identify opportunities for targeted training. If specific workers continually miss aspects of their inspections or replace a component incorrectly, leaders can rectify oversights, leading to professional development. This will level the team's skill sets while encouraging transparent communication between employees.
For example, someone may have noticed the ram is not returning correctly. They reviewed the return spring and replaced it, but it continued to have problems. They may not have known to look for a bent or defective piston, which also needs replacing. A technician’s troubleshooting capabilities may be strong, but records reveal where they could be more comprehensive.
The Top Tips of the Trade
Preventive, proactive measures are the best tactics against hydraulic press failures. These changes are simple to implement with the least amount of upskilling and technology required. Though additional innovations, like sensors and data analytics, can amplify troubleshooting, these strategies are the most tried-and-true methods for consistency. Teams must advocate for training and oversight to keep hydraulic presses in peak operational condition.
