Fall Into Hybrid Motor Winterization

Last week, we wrote about the effects of cold weather on hybrid vehicles. This week, we’d like to follow that story up with some tips on how to actually prepare your hybrid for the coming cold winter months.

The companies who work in hybrid motor manufacturing care greatly about how those motors perform after they leave the assembly line. Eagle Technologies creates the systems that help companies like GM, Ford and Chrysler generate thousands of hybrid cars each year. Many of these cars end up in places such as the freezing ‘M’ states: Minnesota, Maine, and Montana among others. However, these customers often don’t know what it takes to prepare a car for the sub-zero temperatures that these states hold for weeks. Here are a few important tips that you should be aware of:

4 Important Hybrid Motor Winterization Tips

1. Add grill blocks keep the cold air out from under the hood. Cold air rushes into the car as it runs, making it difficult to warm up a car with climate-sensitive parts such as hybrid batteries. A grill block is as simple as a piece of cardboard behind the grill or customized blocks that fit your car perfectly without being obvious. The latter takes time to obtain, so September is a perfect time to place the order.
2. Have the car’s lights, heaters, and defrosters inspected. These items run simultaneously in the winter, and combined with the cold air, will dampen the hybrid car’s performance and gas mileage. Make sure that these components are functioning appropriately to mitigate the performance and fuel economy losses that you cannot avoid.
3. Replace your tires with ones that are designed to handle the snow and cold. Michigan winters are long and harsh on your hybrid car. There’s no need to send it out on tires that are ill-equipped to handle the car outside of normal circumstances.
4. Invest in a block heater if you live in places, such as northern Minnesota, that see extremely low temps for extended periods of time. A block heater warms up the car enough to start it up in such weather.

Proper care of a hybrid engine begins the day you drive it home. Just keep in mind that your half electric, half gas car was not meant to run in frigid conditions that the state of Michigan sees each year. Start early, in September, working with your mechanic to ensure that the hybrid engine in your car keeps running despite the cold.

Filed under: Automative, Hybrid Motors | Tags: cold weather, defrosters, electric motors, fuel, heaters, hybrid, hybrid batteries, Hybrid Motors, maintenance, motor, preventative maintenance, tires, winter | No Comments »

The Chilling Effects of Cold Weather on Hybrid Motors

September usually ushers in the season of Fall in Michigan, the infamous home of the auto industry. However, the industry’s current popular cars, those powered by hybrid motors, may experience a little trouble running in the great state that gave us the American automobile. Hybrid motors do indeed have difficulty functioning in cold weather, the type of weather that Michigan is notorious for.

Cold Weather Hinders Hybrid Motor Fuel Economy (Significantly)

Hybrid cars are known for losing their highly valued fuel economy numbers when the thermostat begins to sink toward 30 degrees Fahrenheit. They can still function, and the drop in fuel economy isn’t so bad when compared to the similar drop in fuel economy for cars that are completely gas powered. According to Hybrid Cars.com, the drop is between 10 to 20 percent no matter what type of engine you have. It’s just that 10-20% can be a bit more significant when taken away from the mere 40 to 50 mpg that you can typically get with a hybrid engine.

Don’t Expect That Cold Hybrid Battery To Be Any Help

The hybrid batteries that help power the cars are also part of the fuel economy problem. When the temperature drops to the 30 degree Fahrenheit range, the nickel metal hydride (NiMH) batteries in hybrid cars will have difficulty functioning. This leads to less than desirable performance and an additional factor that wears on the above mentioned fuel economy. The auto stop functions practically cease until the car has been running for more than 10 minutes, making for a further burn in the fuel department.

A Few More Cold Weather Hybrid Car Quirks..

Here are a few other quirks (courtesy of Autoblog Green) that Michigan hybrid auto owners will notice, and those in say, California, will not:

• The power gauges will show a significant energy draw in colder weather because of the systems needed to heat a car and keep it heated.
• The silent start disappears until summer, leaving you with a car that roars awake like a sleeping bear.

The Autoblog Green and other sources within the hybrid car universe often don’t recommend these vehicles to the residents of long cold winter states, like Michigan, which gets three months or more of freezing weather.

Eagle Technologies prides itself on creating the best machinery for hybrid motor manufacturing, however we haven’t been able to defeat Mother Nature yet. Michigan hybrid cars owners should thus take heed and thoroughly prepare their cars for the winter season. Start now with preventative maintenance, even if it is September, in order limit cold weather problems in your hybrid car.

Filed under: Hybrid Motors | Tags: cold weather, eagle technologies, hybrid, hybrid batteries, hybrid cars, Hybrid Motors, hybrid technologies, preventative maintenance | No Comments »

How to Make the Most Out of Your Customer Service Call

Few people understand that a simple call to customer care can contribute to the development of a new product or an update on an old model. In fact, the relationships between engineering and customer care are an important research and development resource. To help companies like Eagle Technologies implement the much-needed changes required to properly improve a machine, customers should try to get more than just a quick fix out of the call.

1. Come to the call knowing that you did everything as recommended.

   Many of the problems the lead customers to call customer care involve shortcuts taken by the customers. Ask yourself a few questions. Did you assemble/install/set up your equipment according to the instructions and manuals provided? Are you using the machinery in the way it was intended (recommended volume, weight, speed, use duration, etc.)? If your answer is no retrace your steps before calling or be prepared to come clean with the customer care agent in order to get to the root of the problem.

2. Record the data well.

   Make a record of the issues, the time they occur, dates, and a complete description of the problem to relay to customer care agents. Augment this record each time the problem occurs. This will help establish problem frequency and will help the company establish a pattern if the problem seems to be widespread. Your record could also aid in developing an update or modification in future models.

3. Stay calm and be specific when speaking with agents.

   Customer care agents can do a better job at helping you with your problem and relaying information to engineers if they are dealing with a respected client. Stubborn, angry clients have the agents scrambling to please, making the fix more important than the problem. In the relationship between engineering and customer care departments, the problem itself is the most important as it leads to product improvement.

4. Document the contact.

   Each time you go to a customer care agent for help, record the name of the agent as well as the solution given. Relay this information to the agents in future contacts.

When your machine is having trouble, think beyond the fix needed to get production running again. Use your contact with customer care to lead the company on to a something that could end up becoming an asset in a future model.

Filed under: Customer Service | Tags: customer care, Customer Service, eagle technologies, Engineering, machinery, maintenance, product development | No Comments »

Two Ways to Reduce Your Spare Parts Inventory

Continuing with last week’s topic of spare parts, today’s post will review maintaining your spare parts inventory in a way that will actually save you money.

Although a spare parts inventory is usually necessary, carrying enough parts to build a whole new machine is not. In fact, the excess non-vital parts within the inventory can actually be a liability on the balance sheet. Fortunately, you can reduce your spare parts inventory without compromising your productivity – here are two ways to do just that:

Prioritize Your Parts

This will take some time, but the results will amaze you. Many companies working without proper inventory controls are also carrying a lot of unnecessary parts in that inventory. So the first thing to do is to intimately understand the spare parts that you carry, and also the machines that you run.

Next, assign each part to one of the following categories: vital, necessary and ordinary.

• Vital parts are those required in order to keep the entire plant operating. These parts are also difficult to obtain and may need to be custom fabricated, taking an exceptionally long period of time to acquire.
• Necessary parts are for machines that are important for operations, but not business threatening. These parts may take a few days or weeks to acquire. They may also be parts that need replacing often.
• Ordinary parts are those commonly found in the local supply store or those that can be bypassed until a new one arrives. Their breakdown only has a minor effect on production, if any at all.

You’ll need to keep a stock of the vital and necessary parts, but the ordinary ones can be downsized after the next step.

Determine how often certain machinery and parts require repair or replacement. An ordinary part may be the culprit, but the part needs replacing frequently. In this case, the ordinary spares should remain in inventory. Similarly, several spares of a vital part are unnecessary if the part is rarely replaced.

Now, sit down with your equipment and inventory managers, maintenance and repair crew to determine which parts should stay and which should go.

Sub-Contract the Job

Larger companies often form partnerships with parts suppliers to avoid the large inventory expenses. The supplier places the spare parts needed for the company machinery within the plant itself. Only when a part is needed is the plant charged. Otherwise, the supplier keeps track of the inventory. This setup has the added bonus of a tech support staff that the plant can access when the there are issues with the spares.

Whatever your company needs may be, spare parts should not become a burden. They are designed to rescue the plant. Contact Eagle Technologies for more information about our spare parts services.

Filed under: Manufacturing | Tags: costs, eagle technologies, factories, Factory Automation, installation, machinery, maintenance, parts suppliers, preventative maintenance, spare parts | No Comments »

The Importance of Spare Parts Inventories

The manufacturing systems that companies thrive on require more than lubrication and maintenance. They also require spare parts. Most manufacturing and processing companies keep an inventory of spare parts. However, small businesses should also consider creating a spare parts inventory as well.

There are several reasons why a company utilizing machinery should have a spare parts inventory. This includes everything from the parts for an office printer to the processing equipment large enough to fill a warehouse space.

Efficiency

Having parts on hand allows companies to get their operations back online, even after a major breakdown. This avoids lost time and wages while awaiting parts.

Expense

Spare parts are a large expense upon initial purchase, but their costs are minuscule compared to the costs of a breakdown without having spare parts on hand. Depending on the parts needed, the affected machines might need to be shut down while awaiting new parts.

Vital parts may require an entire plant shutdown. Workers and production thus cease while the part is ordered, possibly fabricated, packaged, and shipped. This process could take days or even weeks to complete. Meanwhile, the costs mount for the plant that is sitting idle until the part arrives. Missed production deadlines could even cost the company valuable client relationships.

Proper Repair

Stories abound about company employees who, in an effort to avoid a major shutdown, perform a “patch job” on the equipment. The results are usually even more damaging to the machinery or the machine malfunctions in a way that affects product quality. Making the parts available prevents the need for such shortcuts.

Spare parts inventories are a necessary part of running a manufacturing business. When you order machinery from Eagle Technologies, just ask about adding spare parts to your order.

Filed under: Factory Automation, Manufacturing | Tags: Automated system, costs, eagle technologies, Factory Automation, machinery, machinery repair, maintenance, preventative maintenance, spare parts | No Comments »

Top 5 Signs of Machine Failure

Machine failure is a normal, expected part of the manufacturing process. However, it’s also a costly part of factory automation. From line shutdowns to product delays and even product defects due to the machine failure, costs can rise quickly. That’s why you must stay on top of problems, even before they occur. Here are just five of the many indications of an assembly machine’s eminent failure.

1. Listen for abnormal sounds. Manufacturing floors are loud places, but the people who work on them quickly grow accustomed to the sound of the machines they use. Oftentimes, machinery (their motors especially) emanate a sound that differs from its normal noise. The sound is subtle at first and grows as the problem worsens. Stop and inspect machinery at the first sign of an audible change.
2. Take notice of unexplained heat. There are a number of things that cause enough friction to heat up the metals and other materials used in factory automation. In some areas, heat is expected. But, heat rising from an area that is normally room temperature or colder is a sign of a problem. In addition to friction, electrical issues can also generate heat. The machines should be stopped in order to lubricate or perform a repair. Otherwise, the heat could lead to a fire or seizing of the machine itself.
3. Check for cleanliness. Keeping machines clean is key in a factory. In addition to providing a safe workplace, the cleanliness will also help you spot another early sign of machine failure — leaks. Wetness or dust leaking from a seam, gasket, or other part are all a breach in the machinery. So, an unclean machine may not be a signal of lax maintenance staff, but instead the machine’s signal that something is wrong.
4. Monitor production speed. Slowdowns signal machine failure just as automation speed increases do. Resistance due to several factors, such as lubricant leakage, can cause a speed decrease. Meanwhile, loose rings are one cause of an increase in production speed.
5. Feel for unnecessary vibration. Vibration analysis is one way that plant managers and maintenance teams detect mechanical failures in automation machinery. The change in vibration from the norm is a sign that the machine might have anything from loose parts to lubrication issues.

All companies have their own preventative maintenance and inspection procedures to catch problems in the machinery before they reach crisis capacity. However, the assembly line workers, and others around the machinery, on a regular basis should be made aware of these five things and other small signs that the machine is headed for failure.

Filed under: Factory Automation | Tags: assembly machines, Automated system, Factory Automation, machine failure, machinery, maintenance, preventative maintenance | 2 Comments »

5 Efficiency Tools from the Pharmacy

Manufacturing dispensers are used in several places throughout the factory automation process. Eagle Technologies creates dispensing systems for use in various industries, from automotive to food processing, including pharmaceuticals. Keeping dispenser efficiency high is the goal, one that you can reach by taking a few cues from the pharmacy.

In the pharmaceutical industry, drug dispensers are an important part of the pharmacy. They are designed to dispense the appropriate amounts of each drug. Failure to do so can be harmful to the consumer, so the pharmaceutical industry places much time and effort into ensuring that the dispensers work properly. The lessons learned, especially in dispenser efficiency, can be used in all industries that use dispensers as part of their manufacturing process.

1. Consider your capacity. Dispensers place accurate amounts of liquid and solid materials onto the product being made. Refilling them takes time out of the process. Pharmacists place the drugs frequently requested drugs in larger dispensers. This cuts down on the number of dispenser refills, which results in higher production. You can do the same with your dispensers.
2. Monitor usage. Determine which materials are used less frequently. Place them in small dispensers to avoid waste (or spoilage in the food industry) from sitting unused. Pharmacies do this with perishable medications. Measuring the amount of materials that will be used in one day is another way to reduce waste and increase efficiency.
3. Maintain regularly. Improper maintenance can lead to equipment that runs slow and even suffer frequent breakdowns. Cleaning the dispensers clears out obstructions and helps you catch the signs of mechanical failure before they become problematic.
4. Make labels distinct and clear. Errors are another enemy of efficiency. In the pharmacy, an error can result in harm to the customers and at the very least a shutdown until the problem is rectified. The same scenario occurs in factory automation, resulting in line shutdown and maintenance, depending on the materials involved.
5. Check safety controls. Another means of increasing efficiency is to check the safety controls on the equipment. The valves and switches are there to control the pressure and flow of the materials. When at the proper setting, the dispenser is at its most efficient. Improperly set controls can lead to machine malfunctions and delays.

The pharmacy uses factory automation in a way that is not very different from usage on the factory floor. To get the best usage out of your Eagle Technologies dispensers, try thinking like a pharmacist.

Filed under: Factory Automation, Pharmaceutical | Tags: Automated system, dispensers, efficiency, Factory Automation, Food Processing, maintenance, pharmaceuticals, preventative maintenance, safety | No Comments »

Greasing the Gears of the Food Industry: Food Grade Lubricants

Equipment speed, accuracy and operator safety are all very important concerns in the food processing industry. Millions of dollars go into product testing, research and development in order to make the machines faster, better and safer. However, one extremely important component is often overlooked – the lubricant.

Not just any lubricants can cut it in the food processing industry. They must oil the machines and keep things running. These lubricants are also charged with another duty that their nonfood counterparts do not have, food processing lubricants must protect the food that they come in contact with, without altering the taste, chemical or microbial makeup. Food grade lubricants are necessary for keeping the machine going, and are key to keeping the food safe as well. Unfortunately, these substances are often overlooked.

4 Important Facts About Food Grade Lubricants

1. There’s more than one type of lubricant. The US Department of Agriculture (USDA) has three categories in which approved food grade lubricants are placed.
   • H1 is for lubricants that can safely come in contact with food.
   • H2 category lubricants are those that cannot have any contact with food.
   • H3 lubricants are oils used to prevent rust on components that contact food.
2. There are environmentally friendly options. Plants can borrow eco-friendly lubricants from some nonfood counterparts for H2 category oils. H1 and H3 category lubricants are more limited. Only mineral oils or synthetics are used. Of the two, ester based synthetic lubricants are the more environmentally sound option. They perform well and are biodegradable.
3. Ignoring lubricants can be devastating for your business. According to the trade publication, Machinery Lubrication, there have been several documented cases of contamination from the use of the wrong lubricant.
   • A 1998 case of the use of a nonfood grade gear lubricant resulted in the recall of 490,000 pounds of ham by Smithfield Foods. Consumers reported burning throats and foul tastes.
   • Another case of wrong lubricant usage in 2000 led to the recall of 86,000 pounds of deli meat. Eaters complained of a bad odor and taste along with intestinal issues.
4. Myths abound within the industry. From workers to plant managers and owners, all need to be properly educated about the lubricants used in the plant. Otherwise, you get misconceptions that lead to safety issues. For example, an employee who believes that all lubricants in the plant are food grade can potentially grab the wrong lubricant and contaminate thousands of pounds of food. Another myth is that synthetic food grade lubricants are inferior. In truth, they are designed to perform as well as or better than other lubricants. There is an advantage in using synthetics that are ester based, because these are biodegradable.

The stuff that greases the gears in the food processing plant thus have a larger impact on the company than most people are willing to believe. This underestimation can be hazardous and expensive, especially if the misinformation is plant wide.

Filed under: Food Processing | Tags: eco-friendly lubricants, food grade lubricants, Food Processing, Green, machinery, Machinery Lubrication, maintenance, mineral oils, Smithfield Foods, synthetic lubricants, usda | No Comments »

Products to Cut Farm Energy Costs

How are you saving energy today? That’s the question on the minds of business people around the world …and we have an answer: Condensers, Evaporators & Compressors.

Today’s newest models of this equipment are high in energy-efficiency and can save farmers money on their overhead costs. Condensers, evaporators, and compressors have a wide variety of uses in agriculture and farming. Even minor adjustments to certain systems can increase your energy savings greatly.

Condensers

Condensers are used in a variety of ways, one being in heat recovery systems for dairy farms. The heat from collected milk can be used to heat the water used for cleaning farm equipment. A condensing unit may be more expensive than some alternatives, but the energy savings will make up for the condenser’s initial cost.

Compressors

Compressed air units are used widely throughout farming. Compressor systems use a great deal of energy, but can often improve energy costs in the long term. A compressor consists of a supply side and a demand side. The supply side must be well-maintained to deliver clean air to the demand side. The demand side delivers air to the equipment.

Bringing our attention back to dairy farms, compressors are used to cool milk and to heat water sanitation. If the compressor is operating efficiently, it can cut the energy costs in half for dairy operation.

Food growers use compressed air systems to package their produce for consumers. Growers are able to save money in the long run through the automation capabilities of compressed air systems and the minor equipment changes to be made.

Evaporators

Evaporators are found in large coolers on farms.  These coolers can be used to reduce the temperatures for buildings on the farm. Evaporative coolers are more cost-effective than air conditioners and work better in regions with lower humidity.

Low Costs, High Reward

No matter how you use condensers, compressors, and evaporators on your farm, you will be pleased with the savings when you upgrade your equipment.

Filed under: Green Alternative Energy | Tags: agriculture, air conditioners, compressor, condenser, costs, dairy farm, energy, evaporative coolers, evaporator, Green, heat recovery system | No Comments »

Using Hybrid Batteries in Hybrid Electric Vehicles

There are two major types of hybrid batteries in existance for use in hybrid electric vehicles – lithium ion (Li-ion) and nickel metal hybrid (NiMH).  Many battery subcategories can be found within each.

NiMH batteries were the primary battery source for hybrid vehicles until a few years ago. Today Li-ion batteries are being tested and developed at a quick pace for this usage. Prices for Li-ion batteries were once outrageously high, but are dropping today. Lower prices make the batteries more accessible and thus increase the market for hybrid electric vehicles in the future.

Pros and Cons

Hybrid batteries offer a lot of promise for the future of green alternative energy. Gradually consumers are becoming attracted to the benefits and efficeincies of this technology and away from fossil fuels that can harm the environment. Additionally, with the “unstable” situation in the middle east and oil prices equally unstable …Hybrid Batteries are a safe, stable and welcome alternative.

Hybrid batteries are long-lasting; customers can expect to travel 150,000 miles or more on one battery. Currently, the U. S. government offers tax credits for the purchase of hybrid electric vehicles, making them even more attractive.

Today, Hybrid batteries are a little more expensive than conventional batteries. However, as mentioned earlier, buyers can expect to get a long life from their hybrid battery. With hybrid battery technology improving every day, at some point the batteries will pay for themselves.

The biggest “pro” beyond being “green” is that the Hybrid Battery is allowing today’s vehicles equiped with Hybrid Motors to achieve phenominal gas mileage. Some “city” or “service” vehicles using this technology like buses, delivery trucks, garbage trucks and more, can in some cases see mileage increase between 3 and 10 times. Now that is a “pro”!

Safety Issues

Consumers may worry about the safety of hybrid batteries. Lead was once a major component in manufacturing, but currently technology is safer and lead-free.

The efficiency of hybrid batteries for hybrid electric vehicles must be balanced with the cost and safety. Look for a hybrid battery manufacturer that is involved in research and development. Make sure your hybrid battery has been tested for optimum performance and safety.

Automated Systems for Producing Hybrid Batteries

Your company may need an automated system to aid in manufacturing your own hybrid batteries. There are only a few Automation experts with experience that specialize in systems for alternative energy production. Be sure to choose an equipment builder who has “done it before” to supply you with any automation needs.

Testing equipment for your facility can also be designed just for you. Do some research as to who will provide the best design, installation and service for your business.

Filed under: Automative, Factory Automation, Green Alternative Energy, Hybrid Motors | Tags: Automated system, eagle technologies, Green, hybrid, hybrid batteries, hybrid electric vehicles, Hybrid Motors, hybrid technologies, lithium ion, motor, motor innovation, nickel metal hybrid, NiMH | No Comments »