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COVER STORY
CUSTOM COMPONENTS FOR OPERATIONAL EFFICIENCY
TLX Technologies explain how custom- designed components help reduce long-term costs and improve operational stability
any companies involved in the processing space focus on having well-controlled, stable operations. To achieve this, a critical plan for success involves leveraging planned downtime and scheduled maintenance to make system repairs or improvements and replace components that are nearing their end of life. System improvements can be complex, and they often vary from process to process, but there are some important generalities that can be made related to replacement operations to improve overall efficiency. Companies are taking a hard look at process maintenance, not only in pursuit of the goal of maintaining stable operations but also as an opportunity to reduce costs and minimise downtime.
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provide exact positioning and precise flow control. In addition, a fail-safe position can be designed into the solenoid or solenoid valve, providing assurance that a power failure will not cause unwanted damage to the component or system.
Unplanned downtime reduces productivity and can be potentially dangerous to staff and equipment. Lengthy lead times on replacement parts or waiting for personnel to make repairs only exacerbate the situation. Staff time is a critical cost for any company, so any unplanned downtime can add unexpected costs on top of the decrease in normal product output. Developing a plan for identifying areas that require more work and where components are being changed more often provides the opportunity to develop predictive maintenance schedules to minimise unexpected events as much as possible. For example, if a specific valve type is used in 10 different parts of a system and all of the valves need to be replaced every three months, at least 40 valves will be used every year to maintain operational stability for that system. In this instance, process engineers could investigate the causes of valve failures and then research a more reliable component. Companies may attempt to address the immediate need by choosing standard components, which are readily available and have often been created to provide a quick, cost-effective solution for many different types of applications. The downside is that these “off-the-shelf” products are usually not optimised for any specific
material, process, or fit. Considering a custom valve solution that is better suited for the application and environment could provide greater system stability and long-term savings. If a new custom valve solution provides at least a year of process support rather than just three months, the company will benefit from increased productivity and reduced maintenance costs. Understanding these challenges, TLX Technologies works directly with their customers to develop custom electromagnetic and electromechanical solutions matched specifically to their requirements. The use of core technologies, appropriate material selection, and optimisation of solenoid and solenoid valve design offer opportunities to develop solutions for companies seeking to develop an efficient and reliable component for their system. For applications requiring precise control, proportional solenoids and valves can
12 JULY/AUGUST 2023 | PROCESS & CONTROL
For applications where energy efficiency is a priority, latching solenoids and valves are an ideal solution. They use only a short power pulse to change state and do not require constant power to maintain a commanded position. A power pulse of one polarity latches the armature, which is held in position either by a permanent magnet or residual magnetism. A power pulse of opposite polarity releases the armature. Latching solenoids and valves are particularly useful for battery-operated applications and reduce overall power consumption. Extreme environments offer another challenge that may require high- and low- temperature solutions to achieve optimal performance. When designing for these environments, special attention should be given to material selection and design optimisation to produce solenoids and solenoid valves that provide consistent performance in extremely hot or cold temperatures.
Utilising magnetic modeling and fluid dynamic analysis, an expert engineering team can create the most efficient, best-fit solution, even for applications with the most challenging specifications. The result is custom-designed components that help reduce long-term costs and improve operational stability.
To discuss your next challenging project, please contact TLX Technologies using the details below.
TLX Technologies E:
sales@tlxtech.com
www.tlxtech.com
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