Drive Lines Ltd is a company that provides components used in the construction of portable workstations, also known as Crusers® at Hayward Tyler, which are patent pending.
The Crusers® were named after the late Rob Cruse, who empowered Oliver Buhlinger, a young graduate to invent these solutions. The Crusers® were developed by continuous improvement engineer Oliver with the aim of increasing the mobility of the movement of products weighing up to 40 tonnes to improve workflow efficiency and safety. Drive Lines Ltd was initially a provider of screw jacks. Currently Drive Lines supply Hayward Tyler with couplings, gearboxes, cardan shafts, special combined bearings and profile rails used in the manufacture of the Crusers®.
O Grupo HT (que incorpora os negócios operacionais Hayward Tyler e Peter Brotherhood) projeta, fabrica, testa e fornece serviços de motores elétricos, bombas, turbinas e compressores críticos para atender às mais exigentes aplicações da indústria global de energia. Grande parte deste equipamento de capital crítico de desempenho opera sob condições extremas, incluindo ambientes nucleares, offshore e submarinos. A Hayward Tyler reformulou seu site em Luton para um Centro de Excelência de fabricação, teste e montagem de classe mundial.
To improve efficiency of the manufacturing process, the operations of the overhead cranes were studied. Studies revealed that a safe, more efficient and cheaper alternative to cranes was to transport and manufacture motors and pumps on portable work trolleys. This allows for units to be moved between assembly points with ease along production flowlines. Initial designs incorporated three variations of the trolley, each with onboard equipment for specific duties. The components for the Crusers® will be supplied by Drive Lines.
Oliver Buhlinger explains: “We were looking to redevelop the production floor of over 8,000sqm, including the addition of a clean assembly and test extension area of over 2,500sqm. Being able to start from a blank canvas, we were able to examine all options. To use overhead cranes and forklift trucks would be the conventional approach for moving heavy loads. However, due to the health & safety risks, crane utilisation and ergonomic challenges, an alternative was sought. The key benefits of the Crusers® include the elimination of forklift trucks, reducing crane utilisation by 50% to improve safety and significantly reducing manufacturing costs. The reduced crane utilisation resulted in a cost avoidance exceeding half a million pounds.”
Screw jack systems, bogies and linear guides provided by Drive Lines are used to lift and tilt the stators, and motors whilst situated on the Cruser®. The working platform of the stator can be moved vertically by 350mm, allowing for the working height to be re-positioned. Combined bearings and rails supplied by Drive Lines allow for variable adjustment of the wheelbase ranging from lengths of less than a meter to that in excess of 5 meters.
Os bogies são alimentados por pacotes de energia hidráulica de baixo custo. Os conjuntos de potência podem controlar o levantamento e abaixamento de cada bogie de forma síncrona ou independente para permitir a inclinação dos produtos para outros processos de fabricação. Inicialmente, os mecanismos por trás do ajuste da altura de trabalho deveriam ser acionados eletricamente, no entanto a hidráulica era usada para reduzir custos e garantir proteção contra poeira e água, com uma classificação IP IP66.
“Drive Lines were very helpful when it came to identifying which components to use, a significant benefit when you are in the conceptual stage. Their expertise and experience helped us identify the appropriate parts to be used” stated Oliver.
When a unit is moved from one workstation to another, it is simply hooked up to an electric tug, with which the operator can easily manoeuvre. Crusers® may often be stationary at one workstation for hours, therefore, using detachable tugs, significantly reduces costs for each Cruser®.
The Centre of Excellence was formally opened in 2016 and utilises four Multi-Crusers®, eight ‘Rotor-Crusers®’ and twelve ‘Stator-Crusers®’. The figures of the optimal number of Crusers® on the factory floor have been determined through a factory simulation of future predictions of processes and product movements, which has recently won Hayward Tyler the prestigious Witness Horizon Project of the Year award. Hayward Tyler is also marketing the Crusers® as a standalone product range, suitable for a wide range of manufacturing processes within other industries.
Tendo celebrado seu 200th Anniversary em 2015, Hayward Tyler é um dos mais antigos grupos de engenharia em operação global. Grande parte da sua base instalada global, particularmente do lado da energia, é classificada como crítica, supercrítica, ultra-supercrítica ou ultra-supercrítica.
It attributes its success in part to a philosophy of ‘customer focus, innovation, and a relentless focus on the continuous improvement of its products, its processes and its people’.