How Simple Component Improvements Can Revolutionize Plant Processes

Differing from traditional locking mechanisms, Hyson’s INSTAclamp™ Lock Ring solution features an advanced single-action, double-locking latch that requires no special tools to engage and eliminates failures associated with thread and bolt-style lock rings. (Image: Hyson)

Fast, secure, and reliable systems are crucial in industries where time is money and efficiency is highly valued. One American steel mill experienced frequent downtime because of steel split retention rings falling off during operations, often resulting in chocks falling into the mill during roll changes. The process of reattaching the retention rings was slow and required multiple sets of hands to ensure a more secure fit.

Maintenance costs regarding steel split ring failures were increasing, and the mill needed a solution that didn’t exist.

“The steel split rings were a forgotten aspect of the market,” said Mike Carter, Global Product Manager for Hyson. “The bolts used in the standard components were selected from a catalog and tossed into the solution without any further development. After listening to user complaints, we recognized that this aspect of lock rings needed some additional designing and engineering to improve operations.”

Carter elaborated that the style of the old split rings was so standard that engineers were designing them into applications without a second thought. No one was taking the time to determine if there could be a better solution.

INSTAclamp™ Lock Ring’s advanced retention system provides a pre-set positive clamping force that removes over or under tightening and a 66 percent weight reduction when compared to traditional steel locking mechanisms. (Image: Hyson)

This problem was not unique to this particular steel mill but was prevalent throughout the industry. However, the long-awaited solution finally arrived when Hyson’s team of engineers were approached by someone looking to redesign the product. The team accepted the challenge and began brainstorming.

Working closely with the customer, a Hyson’s dedicated representative took the initiative to understand the needs of the business. In turn, they would relay that information to Hyson’s engineering team. From there, planning, prototyping, and testing solutions began, resulting in a new product in the market that would solve their retention ring issues.

The INSTAclamp™ Lock Ring was developed and the key to its success was a redesign of the locking mechanism. Replacing bolts with a single-action, double-locking latch, the lock ring was a secure solution that offers consistent clamping. The latch also eliminated the need for special tools, eradicating failures commonly associated with thread and bolt-style lock rings.

The new solution featured several design changes that met the market’s needs for a no touch, ergonomic product. The INSTAclamp Lock Rings from Hyson are manufactured using military-grade aluminum, providing a 66 percent weight reduction compared to traditional steel locking rings. This weight reduction significantly decreases the strain on the user, making the process more manageable and efficient.

Additionally, they are designed as a drop-in solution that can be easily installed and uninstalled in just seven seconds, ensuring minimal disruption to operations.

The innovation of the INSTAclamp Lock Ring instantly revolutionized the steel mill’s operations. Safer, efficient, and more secure, the lock ring’s improved attachment style demonstrates the impact a simple component can have on an entire operation. Through intentional re-engineering of a standard design, improvement of operations can infect the entire business and lead to better output.

Following the successful six-month test of the INSTAclamp Lock Rings, the steel mill embraced the Hyson system and has continued to use it for more than a decade. The tension of the spring holds the latch in place until the operator intentionally applies force to unlatch the ring, providing an extra layer of security and peace of mind.

“The actual people that use it love it because of the ease of latching and unlatching,” said Carter. “There is no guess work regarding if it is secure or not. The managers like that they can visually confirm the latch is attached and tight.”

Since its introduction, dozens of steel mills — ranging from hot to cold and bar to sheet — have recognized the benefits of incorporating INSTAclamp Lock Rings into their operations. Despite a redesign with a new material, the product is not restricted by which mill types it can operate within.

Mills do not need to make any changes to their operations when switching to the INSTAclamp Lock Rings. The rings are designed to seamlessly fit the chock, eliminating the need for costly modifications or adjustments.

The success and widespread adoption of INSTAclamp Lock Rings in the steel industry demonstrates the significant impact that innovative solutions can have on improving efficiency and reducing costs. Commitment to providing cutting-edge products that address industry challenges undoubtedly revolutionizes how businesses can operate.

Tim Barill is Regional Sales Manager at Hyson (Brecksville, OH). For more information, visit here .