More And More Colleges Are Realizing How Vital It Is To Teach Students Hydrostatics
Rory McLaren
Founder/Director/Teacher/Author/Red Seal
As the critical shortage of competent fluid power technicians continues to grow, companies continue to haemorrhage dollars. Over 85% of the hydraulic components that are removed from hydraulic systems have nothing wrong with them. Untrained mechanics toil for hours trying to solve simple problems with hydraulic systems. It costs companies tens of thousands of dollars to airfreight unneeded components to downed machinery and equipment, and also to pay unnecessary overtime wages.
Six weeks ago I conducted three workshops in two different companies in Texas. There were twelve field-service mechanics in each workshop. There is a common theme when I conduct troubleshooting workshops. , one student after another told me stories about the numbers of hydraulic components they replaced because they didn't have the training or knowledge to troubleshoot simple hydraulic problems.
In one instance alone the untrained mechanics replaced eight hydraulic pumps before they stumbled on a solution. I began to make a note of each instance. After three weeks of training, I estimated that the 36 mechanics had cost their respective companies approximately $250,000.00 in unnecessary component replacement alone.
The lion's share of the losses was related to hydrostatic drives - in particular, Sauer Danfoss 90 Series. A Sauer Danfoss 90 Series is a superb product. The problem is there aren't enough mechanics that can set-up, adjust and troubleshoot them. The same applies to other reputable hydrostatic transmission manufacturer's like Rexroth, Parker Denison, Eaton, Linde, etc.
Technical colleges needed to do a better job of teaching state-of-the-art hydrostatic transmissions with electronic displacement control valves. Five years ago FPTI embarked on a mission to develop a solution. Colleges needed a hydrostatic transmission simulator that was first and foremost safe. It needed to be fully-functional with variable load capability. Finally, it needed to have the ability to enable every fault (electrical and mechanical) listed in the troubleshooting section of a hydrostatic transmission manufacturer's service manual.
One and half years after we began the exhaustive task of designing and building a fully-functional, drive capable hydrostatic transmission training simulator, which is about the size and design of a skid-steer type loader, the Model MF500 was born.
It's obvious that some technical colleges have recognized the need for world-class hydrostatic transmission training. This year we shipped a record number of MF500 Hydrostatic Transmission Training Systems to colleges in the U.S.A. and Canada. We also delivered a unit to a military training centre in Australia.
MF500 undergoing intensive pre-delivery testing at FPTI's manufacturing plant in Salt Lake City, Utah.
Note: The MF500 can be drive in realtime with or without load. In the photo, the technician is literally driving the MF500 up a hill with a full load. The system's flow and pressures are identical in every respect to an actual skid-steer loader operating under the same conditions.
From time to time I get into a discussion with college instructors about the cost of the Model MF500 versus the cost of purchasing a used skid-steer loader. I respect the fact that technical colleges are hard-pressed for cash. However, a college's primary responsibility is to provide the industry with a competent and efficient workforce.
Let's look at the situation from the point of view of return on investment (ROI). It's a foregone conclusion that college's that utilize the "cheaper" skid steer loader option aren't doing very well. Over 99% of the students that graduate from college cannot pass a hydrostatic transmission competency test.
Rather than looking at it from the point of view of how much the college saves by purchasing sub-standard training aids, one must look at it from the point of view of how well a competent technician will serve his or her industry.
For example, the cost of a used skid-steer loader is approximately $25,000.00. The cost of a hand-built MF500, which is designed and built for the specific purpose of training is approximately $50,000.00. Now weigh that that against the cost of a hydrostatic drive on an oil-field service rig, or a mining machine, which is approximately $25,000.00.
If only two students saved the companies that employed them $25,000.00, surely the investment in the MF500 was well worth it.
Of course, there is the issue of safety. A skid-steer type loader is arguably the most hazardous type of machine that can be employed in a college lab. In many cases, instructors have to disengage vital safety devices to permit students to perform work in the bowels of the unit while the engine is running. One also has to consider noise, exhaust emissions, heat from engines, oil-spillage, lifting off the ground, rotating wheels, bucket falling, etc.
Notice that the wheels on the skid-steer loader in the photograph is too close to the floor and the jacks. There must be sufficient space between the wheel and the floor to prevent a student that is either laying on the floor or on a creeper from getting snagged in the rotation tyre.
MF500 Specifications:
Hydraulic pumps - dual Sauer Danfoss M46 pumps with electronic controls.
Wheel motors - dual high torque low-speed gerotor type motors.
Power unit -
Option 1 - 25-HP electric motor constant speed
Option 2 - 25-HP electric motor variable speed (VFD)
Option 3 - Diesel engine
Safety features:
Wheels are fully-enclosed with transparent Lexan covers
Two (2) emergency stops (one per side)
Safe-T-Bleed energy control devices
Reservoir capacity - 90-gallons
Price includes an extensive curriculum with PowerPoint slides and superb animations. It also includes an outstanding textbook and workbook.
Photo of MF500 with optional hydraulic steering and bucket control training systems:
For more information visit our website - www.fpti.org
For a proposal contact Matt at 801-908-5456
No comments:
Post a Comment