Machine tool cleaning in the metalworking industry and the tooling industry
Regular cleaning of machine tools should be an essential part of any maintenance plan. In practice, however, this means hours of tedious manual work, and standstill of the machines at the same time.
With the unique ph-cleantec process, on the other hand, the cooling lubricant of the machine tool is sucked in and heated, and the machine tools are cleaned effortlessly and in the shortest possible time with their own cooling lubricant. This motivates the colleagues and, above all, saves time and money.
The correct cleaning of a machine tool is still an unpleasant and time-consuming task in practice. Small and medium-sized machine tools in particular are very compactly designed and combine a large number of functions in a very small space. In terms of cleaning, this means .... very difficult access!
The actual machining cabin is often still easily accessible, while the tool magazine or the drive area with the spindle are rather filigree and difficult to access. But it is precisely these zones and especially the tool magazine that require proper and regular cleaning. Adhesions due to coolant or oil or chips can cause damage to the tool holders and the handling systems.
Cleaning with high pressure is out of the question because the pressures and enormous amounts of water would damage and rinse out the bearings. The use of rags and brushes is only possible where one can reach and, in addition to insufficient cleaning, often involves considerable risks of injury. Moreover, cleaning by hand is very time-consuming and in no proportion to the result.
Proper cleaning of a tooling machine is still an unpleasant and time-consuming task in practice. Small and medium-sized tooling machines in particular have a very compact design and combine a large number of functions in a very small space. Regarding the cleaning process this means …. it’s really difficult to access all these parts!
The actual "machining area" is often still quite accessible, while the tool magazine or also the drive area are rather filigree in design. But it is precisely these zones and especially the tool magazine that depend on proper and regular cleaning. Stickiness due to coolant or oil or chips can cause damage to the tool holders and the handling systems.
Cleaning with high pressure is out of the question because the high pressures and enormous amounts of water would damage and rinse out the bearings. The use of rags and brushes is only possible where one can reach and, in addition to insufficient cleaning, often involves uncomfortable risks of injury. Moreover, cleaning by hand is very time-consuming and way too costly for the result.
The ph-cleantec low-pressure hot cleaning technology works more gently, efficiently and quickly!
The process combines a pressure of 3 to max. 14 bar with a high working temperature of 95°C. This is reached within one minute by means of an electric flow heater.
The low pressure ensures that no damage or spraying effects occur; handling is done by means of a lance. The lance is narrow enough to access hard-to-reach places; a rinsing volume of only approx. 2 l/min ensures that the cleaned dirt is removed properly and that no bearings are washed out.
The operator does not have to reach into the machine with his hands; thus injuries can be excluded. The tools remain in the holder and are cleaned at the same time as the holders.
The time saving compared to manual cleaning is enormous. A tool magazine with e.g. 60 places can be cleaned in a few minutes.
As a medium the machine's own cooling lubricant is used. This means that cleaning can be carried out at any time without the emulsion being watered down or – worse - tipped over by alkaline cleaners; no foreign substances are introduced. The coolant can be filled into the machine tank or sucked in directly from the tank of the tooling machine.
Apart from the tool magazine and the drive areas, the entire machine and the periphery can of course be kept clean with the low-pressure hot cleaning process.
In combination with an on-top parts cleaning level, the ph-cleantec units can also be used as mobile washing tables for parts cleaning during repair or maintenance or for degreasing production parts.
Another option is to thermally sterilise the cooling lubricant in bypass-mode. This reduces resp. avoids the use of aggressive fungicides or bactericides.
During the production or while the application of tools with internal cooling, the cooling channels need to be cleaned very neatly. However, the accessibility of the tight clearance holes is quite difficult with the conventional cleaning procedure.
Solution approach with ph-cleantec
The tools can be integrated in a compression fitting. On the opposite side the pistol is connected to the low pressure hot cleaning device.
With a pressure of 3 to 8 bar and 95°C hot water the cooling channels can be rinsed efficiently with a flush volume of ca. 1,8 l/min. The water can be added with alkaline detergent, if necessary.
Advantages with the ph-cleantec cleaning technology
- High accessibility
- Fast and simple change of tools
- High efficiency
- Universal procedure, inter alia for the machine cleaning and periphery
- Cleaning of 1,600 connecting rods in series production
- Small design of device; means little space requirement
- Low cost solution
- Integration of cleaning machine into the system control technology
- Pistol no longer required and replacement through ring nozzles; operated by a slow electrovalve
- Use of cooling lubricant in the system cycle
- Cleaning machine especially designedfor continuous operation.
- Compact design; easy to be integrated
- Mode of action of the low pressure hot cleaning
- Cleaning system operated with machine cooling lubricantand thus very good lubricating and corrosion protection properties
- Less use of resources
- Very good cost-performance ratio
Automated flange cleaning
Extrusion means the processing of plastics.
After the liquid plastic has been obtained, it is pressed via a nozzle into a so-called calibration (tool), which has the shape of the future profile. During these thermal processes, waxes are released or added as lubricants. These waxes harden in the system and must therefore be cleaned.
Nowadays, a wide variety of profiles are produced by means of extrusion. Mostly, the material is cooled in a water bath after forming.
Advantages of low-pressure hot cleaning technology
- Optimum accessibility in complex tools, e.g. the various cooling channels can be cleaned very well with our tools.
- Our devices can also be used directly in the plant, as usually the profile is cooled down in a water bath
- No aggressive cleaners
- Compared to ultrasonic bath an efficient and fast process
- Corrosion protection can be added if necessary
- Mobile system