When a magnet is received, the first step is to assign it to a Job
Number and complete a "Magnet Service Report." Each magnet is
electrically tested and mechanically inspected to determine the
condition of the magnet. |  |
Next the magnet is disassembled by machining or a controlled arc process. The parts are then inspected, noting those needing reconditioning or
replacement. At this point a quotation is prepared and sent to the customer.
|  |
After the quotation has been approved by the customer, mechanical
parts are cleaned and sand blasted in preparation for reassembly. |  |
The copper or aluminum conductor is then cleaned and inspected,
noting any that are out of specification or needing replacement. Failure
to replace conductor with the same gage leads to premature failure. |  |
Engineering then creates a Computer Aided Design (CAD) drawing for the
production department along with a detailed bill of materials for the
store room. |  |
Coils are wound turn by turn with Nomex insulation in between each
turn. When winding aluminum, the last three turns are wound with copper
conductor. |  |
After winding, the coil is tied off with vertical straps of copper.
Alcuplate is used to join the aluminum conductor to the last two turns
of copper conductor. Alcuplate prevents galvanic corrosion and Walker is the only manufacturer to use this quality material.
|  |
Components are inspected against O.E.M. drawings and remanufactured
to the latest revision. Following a milling process, the magnet is
ready for reassembly.
|  |
After the coil is installed in the case and properly insulated, the
bottom plate is inserted and pressed to 4000 psi and tack welded. The
magnet is then heated to 300º F to remove moisture before being semi-automatically welded to permanently create a water tight seal. |  |
The magnet is then vacuum impregnated with a
specially formulated insulating potting compound and baked to over 350
degrees to produce a water tight fit and cure the potting compound. |  |
In this final stage, all magnets are then electrically tested. The
values are recorded to create a historical record in their individual
folder as part of a future failure analysis process. |  |
Prior to shipment, the magnet is painted and fitted with new pins.
The chains are reattached and inspected for wear. The customer is
advised if chains appear worn. The completed magnet is ready for
shipment or to be put in a customers individual Magnet Exchange Program
inventory. |  |
Whether on a contract carrier or our own trucks, Walker
delivers the highest quality new or re-manufactured magnet to your
facility. |  |
