Background
K&R Hydraulics were contacted by Molycop to carry out the complete overhaul and modernisation of two main Carriage Cylinders.
Molycop manufacture wheels for Rolling Stock in their Mayfield (NSW, Aus) based Rail Products, Edge Water Mill (EWM).
The site produces the steel in an Electric Arc Furnace and ingots are cut, then forged to a Rail Wheel.
The Mill then rolls the wheel to the predefined size and shape, ahead of final machining.
The Problem
A very tight window of just 2 weeks was allowed for the complete overhaul and modernisation.
K&R’s project team pre-planned, procured, pre-engineered and pre-machined every component in order to meet this time frame.
The Cylinders had originally been installed in the mid 1930’s ran on high pressure water. They were converted to Oil Hydraulics in the 1960’s.
As such, they are a design with a “liner” in the bore and used copper and leather for sealing. Some major components within the Cylinders have heavily eroded over time.
The Solution
The two Carriage Cylinders, 8” Bore, 6” Rod and 95” (2.4m) Stroke, were completely overhauled, modernised and tested within the time frame. The before and after photos give an insight to the external change but the real work was internal, where we:
- Replaced the lining bore sleeves using our 500 tonne horizontal press.
- Modified the gland to enable fitting of the Modernised Sealing Arrangement.
- Machined and reclaimed porous and water eroded end caps.
- Performed Cycle testing.
Feedback from Molycop
“Thankyou K&R. The Cylinders arrived this morning and are going in now. They look really good. Very nice work.
Hopefully they run as good as they look. I reckon they might have dropped out of the “top 10 ugliest cylinders” list, into the top 10 prettiest!
