landroversforever Posted January 30, 2023 Share Posted January 30, 2023 Epic! How many tonnes a year does the plant make? Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted January 30, 2023 Author Share Posted January 30, 2023 10 minutes ago, landroversforever said: Epic! How many tonnes a year does the plant make? Its done around 750,000 tonnes a year in my time here but we are now improving to hit 1,000,000 within 5 years regards Stephen Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted January 30, 2023 Author Share Posted January 30, 2023 15 minutes ago, Gazzar said: Why did the shaft break? Was it the support? Or just fatigue? Looks like Fatigue, you can see shading where its been cracking, not easy to find with NDT as its snapped about 40mm inside the roller regards Stephen Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted January 30, 2023 Author Share Posted January 30, 2023 18 minutes ago, steve b said: I had the chance to do an engineering club walk round of our local cement works in operation ( now a housing estate...) many years ago and the kiln hall is like nothing else in industry. How does a failure like that impact the continuous nature of the process? Steve Was that Masons works near Ipswich ? Production has stopped for at least a week in order to repair regards Stephen Quote Link to comment Share on other sites More sharing options...
steve b Posted January 30, 2023 Share Posted January 30, 2023 It was - Blue Circle. I have a piece of the huge chimney's concrete as a momento when it was dropped. I suspect the shaft failed due to slow bearing failure causing bending of the shaft as it rotated. Time for some early warning sensors of some sort maybe? Steve Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted January 30, 2023 Author Share Posted January 30, 2023 4 minutes ago, steve b said: I suspect the shaft failed due to slow bearing failure causing bending of the shaft as it rotated. Time for some early warning sensors of some sort maybe? Steve Not bearing failure, bearings are bottom half brass only no top with a constant oil feed, the break pattern on the roller shaft suggests its being flexing and cracking over a period of time regards Stephen Quote Link to comment Share on other sites More sharing options...
steve b Posted January 30, 2023 Share Posted January 30, 2023 Very interesting stuff. I do find heavy industry fascinating. So much of our local heavy industry has gone, very glad to have seen most of it up close and working. Steve Quote Link to comment Share on other sites More sharing options...
landroversforever Posted January 31, 2023 Share Posted January 31, 2023 9 hours ago, steve b said: Very interesting stuff. I do find heavy industry fascinating. So much of our local heavy industry has gone, very glad to have seen most of it up close and working. Steve Likewise! Thankfully managed to see didcot A coal power station running before it was decommissioned. Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted February 27, 2023 Author Share Posted February 27, 2023 On 4/17/2022 at 1:58 AM, Stellaghost said: Remember these The gearbox table that rotates these was cracked and has been welded up the following pictures are of the milling device contracted in to cut the gearbox table level again so track segments can be fitted Mill rigged up from a central pivot point Remember this table getting Machined Well new table arrived today all 70 tonnes of it regards Stephen 4 Quote Link to comment Share on other sites More sharing options...
Daan Posted February 27, 2023 Share Posted February 27, 2023 Surprised that came from holland. Quote Link to comment Share on other sites More sharing options...
elbekko Posted February 27, 2023 Share Posted February 27, 2023 45 minutes ago, Daan said: Surprised that came from holland. Could be Mammoet was just doing the transport. 1 Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted February 27, 2023 Author Share Posted February 27, 2023 51 minutes ago, Daan said: Surprised that came from holland. 5 minutes ago, elbekko said: Could be Mammoet was just doing the transport. Pretty sure table was made by Renk in Germany regards stephen Quote Link to comment Share on other sites More sharing options...
steve200TDi Posted March 1, 2023 Share Posted March 1, 2023 Is it being craned onto the milling table? Looks like it might be craned in through the roof. Where's its new home? Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted March 1, 2023 Author Share Posted March 1, 2023 1 minute ago, steve200TDi said: Is it being craned onto the milling table? Looks like it might be craned in through the roof. Where's its new home? Not going through the roof, gearbox etc will be removed and new table lifted up from underneath, then gearbox put back into position Regards Stephen Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted March 1, 2023 Author Share Posted March 1, 2023 3 hours ago, Stellaghost said: Not going through the roof, gearbox etc will be removed and new table lifted up from underneath, then gearbox put back into position Regards Stephen These double roller sets at 75 tonnes each run on wear plates mounted onto table, rollers remain static and table turns underneath the table is driven by a large gearbox that the new table will attatch to through put of mill is around 275-300 tph Regards Stephen 2 1 Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted March 8, 2023 Author Share Posted March 8, 2023 Another dull day at the office... 19E1F4E2-~3.mp4 .....lol Regards Stephen 2 Quote Link to comment Share on other sites More sharing options...
Gazzar Posted March 8, 2023 Share Posted March 8, 2023 I love proper factories. I had the privilege of a tour of an aluminium foundry once apon a time, rivers of molten aluminium running through a building. Thanks for sharing. 2 Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted March 8, 2023 Author Share Posted March 8, 2023 7 hours ago, Gazzar said: I love proper factories. Think I must too... Will have 44 years service in August, same company in its many guises... Regards Stephen 2 Quote Link to comment Share on other sites More sharing options...
Peaklander Posted March 8, 2023 Share Posted March 8, 2023 9 hours ago, Gazzar said: I love proper factories I worked at Honda Swindon for a few years, in the engine plant. We melted aluminium ingots at one end, cast the block, gearbox cases (high pressure) and head (low pressure with sand moulds), machined it all, (hobbed the gears in later years) and then assembled and test fired every engine. This was across two production lines in one single level building. It was about 100m x 100m that's all. The most amazing place you would ever see; a proper modern precision factory. It's so sad that a change in strategy caused Honda Corp to close it. Quote Link to comment Share on other sites More sharing options...
landroversforever Posted March 8, 2023 Share Posted March 8, 2023 Just now, Peaklander said: I worked at Honda Swindon, in the engine plant for a few years. We melted aluminium ingots at one end, cast the block, gearbox cases (high pressure) and head (low pressure with sand moulds), machined it all, (hobbed the gears in later years) and then assembled and test fired every engine. This was across two production lines in one single level building. It was about 100m x 100m that's all. The most amazing place you would ever see; a proper modern precision factory. It's so sad that a change in strategy caused Honda Corp to close it. Still gutted that I never chance to look round there. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted March 8, 2023 Share Posted March 8, 2023 That would have been amazing. I got to see a Toyota assembly plant in Japan a few years ago. I saw the assembly line and robot monocoque assembly. Quite cool indeed. Saw land cruiser drive line assembly. Quote Link to comment Share on other sites More sharing options...
landroversforever Posted March 8, 2023 Share Posted March 8, 2023 Closest I've had was seeing the Mini production line sometime after the R56 was first built. Impressive seeing the robots spot welding the shells, but even then, the pressings are made off site in Swindon. Quote Link to comment Share on other sites More sharing options...
elbekko Posted March 8, 2023 Share Posted March 8, 2023 2 hours ago, Stellaghost said: Think I must too... Will have 44 years service in August, same company in its many guises... Regards Stephen That's impressive. I used to work with a guy like that. 40+ years with the company. Had done pretty much every job in the factory except for upper management. Knew everything and everyone. He was in his 70s and didn't want to retire, as he'd just be bored at home anyway. Quote Link to comment Share on other sites More sharing options...
Peaklander Posted March 8, 2023 Share Posted March 8, 2023 1 hour ago, landroversforever said: the pressings are made off site in Swindon I have seen that press - they made the bonnets for the Honda Concerto amongst other things and also panels for Roll Royce. 34 minutes ago, elbekko said: I used to work with a guy like that. 40+ years with the company. I might have mentioned this somewhere else on here before but I went to work at a company and needed to give a speech at the long service awards dinner. A recipient was up for his 40 year award. I was only 36 years old and it was very humbling. Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted August 23, 2023 Author Share Posted August 23, 2023 So cross screw on my new to me milling machine stopped working, so stripped it out, whilst I was doing this I noticed a few ball bearings kicking about, hmm must have a bearing collapsed No, the balls were out of cross screw nut... I now know they are called ball screws, never seen and never heard of them The balls run around that tube will be fiddly to go back Ordered some new balls, so will see how I get on regards Stephen 2 Quote Link to comment Share on other sites More sharing options...
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