N O T E S & T I P S
PREVENTATIVE MAINTENANCE and UPGRADES
Preventative maintenance is a necessary and important function to ensure proper and efficient equipment operation. PM is a maintenance that is performed on a regular schedule to prevent major equipment failure. It is less costly to perform PM than to repair equipment and experience production downtime.
The three keys to Preventative Maintenance are:
Cleanliness is more that sweeping the floor. When it comes to equipment, it is important that lint, dirt and grease are kept clear of equipment components. These components include but are not limited too, belts and ribbons, gears and sprockets, filters, electrical contacts and controls, ironer chests, etc.. A good PM Cleaning program will help assure that all types of systems are operating at peak efficiencies.
Performing a physical inspection of equipment helps identify potential problems. Utilizing ones senses of sight, sound, smell and touch are all part of a complete inspection. Inspections will help identify bearing and bushing failures, electrical contacts pulling high amps, heat loss, loose parts, misalignment and so forth. By identifying potential problems prior to complete failure will save time and money.
Lubrication is the life blood of moving parts. By periodically applying grease or oil to bearings, bushings, chains and gear boxes, equipment life will be extended. A firm schedule of recommended lubrication should be followed.
IRONER FEATURES AVAILABLE
It was discovered during the early days of flatwork finishing that a single speed resulted in inconsistencies with the quality of the finished products. Hence, we witnessed a progression of speed control devices ranging from multiple speed motors, variable pitch belts, DC motors, and hydraulic systems. Each of these types of speed controls are limited in adjustments, expensive to operate, and maintenance intensive.
The development of the inverter drive system is the latest technology available today. We no longer have to deal with fixed speeds, unreliable mechanical systems or messy and inefficient hydraulics. The advantages of the inverter are as follows:
Infinite control so the ironer speed can be adjusted to obtain the
optimum finish of the various textile blends.
Speed adjustments are as simple as turning the speed control knob.
~ Eliminates Component Stress
Provides for a soft start with controlled acceleration to a preset speed
which eliminates shock loading of drive components during start up.
~ Energy Cost Reduction
Eliminates electrical amp surges due to ramp up current which in turn
will lower the electrical surcharges based on peak amp demand.
Provides instant stopping for maximum operator safety. Has a
reversing circuit which allows the ironer to run in the reverse mode.
This is an OSHA recommendation for maximum operator safety.
Inverters have been on the market for several years offering consistent
and reliable performance.
IRONER DRIVE CONVERSIONS
The original manufactured drive system is a very cumbersome and expensive
system to operate. There are two types of drives available today to reduce
operating costs, improve safety and minimize floor space. They are the
Herringbone and the exclusive C&W Chain Drive. Each of these types eliminate the reeves drive, clutch linkage, 3 groove sheave, clutch, main drive thru shaft, and pinion gear. The new drives are located on the right side of the ironer where all of the drive gears and/or sprockets are located.
This drive is less expensive than the Chain drive as there are fewer components replaced. The ironer continues to operate with a combination of gears and sprockets as originally designed. A Herringbone Drive consists of ; 80 tooth gear/sprocket, gearbox sprocket, motor and gearbox, chain and inverter control.
C&W Chain Drive
In addition to the elimination of the original drive components described above, this drive virtually replaces all of the original gears, herringbone gear, intermediate shaft, apron drive system and feed board drive. This drive utilizes all new sprockets and chains, which are automatically lubricated by the Auto Oiler System. This drive is also located on the right side of the ironer and includes a new motor, gearbox, and inverter control.
MODULAR SIDE COVERS
The original manufactured side covers are one piece construction which is difficult to remove and replace. Consequently, many times the proper preventative maintenance is not performed and/or the covers are not replaced leading to safety concerns. C&W has developed a modular light weight side cover that is easily handled by a single technician for servicing.
LOW PROFILE CANOPY
C&W has designed and manufactures a low profile canopy. It is a modular canopy that is constructed of aluminum frame with mylar windows. This canopy rests on top of the ironer eliminating the need for any ceiling support. By fabricating the canopy in multiple sections, it is easily removable for cleaning and ironer maintenance. By utilizing the low profile design, vision is not obstructed amongst workers and management. The clear mylar windows offer a clear view of the rolls.
SPRINGPRESS ROLL SPRINGS
Vacuum assisted ironers are manufactured with springs covering the rolls. These springs allow air flow between the roll and its covering to help evacuate moisture. The also improve the finish and extend the life of the covers. As a norm, roll springs should be replaced every 8 to 10 years. Springpress is the leading manufacture of roll springs. Springs are available in multitude of sizes to offer optimum performance in all types and manufacturers of ironers. One size does not fit all.
ROLL VACUUM EXHAUST
The roll exhaust system assists the ironering process by removing moisture from the product. The quicker the moisture is removed, the faster the ironer can run resulting in higher productivity. C&W has increased the CFM exhaust on the replacement blower motors. A good maintenance practice would be to periodically clean the vacuum system on the ironer of any wax build up.