At AC Engineering Services, we specialise in providing high-quality refurbishment solutions that extend the life of heavy-duty industrial equipment. One recent project involved a mobile crusher plate feeder that had been brought in for refurbishment due to significant wear and the presence of cracks. This case highlights our expertise in restoring equipment to peak performance while incorporating design improvements to prevent future issues.
Proudly Serving Stockport and Beyond
With our commitment to excellence, we are proud to serve businesses in Stockport and the surrounding areas. This recent refurbishment project is just one example of how our engineering solutions support local industries, ensuring their equipment remains reliable and operational.
The Challenge
The plate feeder in the mobile crusher had suffered excessive wear and structural damage, compromising its functionality. The feeder was critical to the crusher's operation, as it controlled the flow of material into the machine. The wear and cracks posed risks of failure, leading to potential downtime and costly repairs for the customer.
The main objectives of the project were:
• To remove the damaged plates.
• To redesign and manufacture replacement components.
• To enhance the structural integrity of the feeder through additional reinforcements.
Our Solution
Step 1: Removal of Worn Plates
Using air arc cutting technology, our team carefully removed the worn and damaged plates from the feeder. This method allowed us to cut through the materials with precision, ensuring minimal disruption to the surrounding structure.
Step 2: Structural Reinforcements
To address the issue of cracks and enhance the overall strength of the feeder, we added fully welded bracings. These reinforcements were strategically placed to provide additional support, improving the feeder’s ability to withstand heavy loads and vibrations during operation.
Step 3: Redesigning the Finger Plates
The original finger plates showed signs of excessive wear due to their material and design. To improve durability and performance, we re-designed the finger plates and manufactured them using 20mm HARDOX plate—a high-strength, wear-resistant steel ideal for heavy-duty applications.
The plates were:
• CNC Plasma Cut: Ensuring precision and uniformity in the shapes.
• Drilled and Countersunk: Providing a secure fit that reduced the risk of loosening during operation.
Step 4: Reassembly and Final Inspection
Once the new components were fabricated, the plate feeder was reassembled with meticulous attention to detail. The new finger plates were installed, and all reinforcements were inspected to ensure they met our high-quality standards.
Step 5: Transport Back to the Customer
After the refurbishment, the plate feeder was loaded onto transport and safely returned to the customer in Stockport, ready to be reinstalled and put back into service.
The Result
The refurbishment process resulted in a plate feeder that was stronger, more durable, and better equipped to handle the demanding conditions of mobile crushing operations. The use of HARDOX steel for the finger plates and the addition of fully welded bracings significantly enhanced the lifespan and reliability of the equipment.
Customer Benefits
• Reduced Downtime: The feeder was refurbished and returned to the customer promptly, minimising operational disruptions.
• Cost Savings: By refurbishing instead of replacing the feeder, the customer avoided the higher costs associated with purchasing new equipment.
• Improved Performance: The redesign and use of high-quality materials provided better resistance to wear and increased operational efficiency.
Why Choose AC Engineering Services?
At AC Engineering Services, we pride ourselves on delivering tailored engineering solutions that meet and exceed customer expectations. Whether you’re in Stockport or further afield, our team’s expertise in refurbishment, precision machining, and design improvements ensures your equipment performs at its best for years to come.
If you’re facing similar challenges with your industrial equipment, contact us today to discuss how we can help. Let us bring your machinery back to life!
