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fluid, filtration & chip managEment
Examples of our approach to a harmonized solution for plants using wet machining
processes would incorporate the types of technology found in the next 4 examples,
which we installed at Strategic Manufacturing Solutions, LLC.
(Videos/Photos courtesy of Strategic Manufacturing Solutions, LLC):
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PUMPBACK UNITS
Properly sized machine discharge units not only collect the fluid and the chip stream but are designed to ensure no areas are building up with fines and solids to create bacteria, and odor. By positively pumping on demand, our smaller pumps/motors utilize less energy to move the stream towards the customers remote filtration system. With small, dedicated, and easy to maintain return and supply lines, the design requires no flumes, no floor conveyors and we keep much smaller volumes of coolant in the closed loop process. WATCH MOVIE
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| REGIONAL OR CENTRAL FILTRATION
With a smaller volume of fluids to manage, the customer can still use the type of regional or centralized collection system as shown here, but will require a smaller size. This in turn requires small pumps and motors as part of our Lowest Life Cycle Cost approach. In keeping with Zero Waste this unit is designed with no roll media, instead using a semi-permanent belt and drag out system for bringing the solids out of the system. With the discharge ready for post processing a vacuum extraction system can be used to deliver the chips outside, clean and dry.
WATCH MOVIE
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| DELTA FORCE ULTRA-FINE FILTRATION
After the primary stream is filtered and returned as a “flood and flush” stream to the machine tool, a portion of the clean material is slip-streamed with a 2-5 absolute Micron in-line filtration system using Permanent Media for removal of the fines. This technology was developed and benchmarked against traditional paper or belt systems with the objective of providing the cleanest coolant stream possible. The unit shown here not only
supplies the “thru-the-tool” requirements, it continuously overflows into the primary system to improve its cleanliness as well. WATCH MOVIE
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| AIR EMISSION DISCHARGE FROM PROCESS
The emission levels of machines not only need to meet the customer requirements of providing clean air, it needs to meet the ever demanding and more difficult levels of less than .05 mg/cubic meters of exhaust levels, as well as have the Hepa Filters last 10,000
hours without change out. (In the Auto and Union Facilities) The technology is very modular, and designed to re-circulate the clean air and not exhaust out of the building saving considerable energy and air make up costs. Using pre-separation and primary/secondary media which can last up to 10 years the units are very low maintenance and very robust, providing a great flame barrier as well. WATCH MOVIE
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Examples of our approach to a harmonized solution
for plants using Dry/MQL machining processes would be incorporating the types of technology found here:
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| MACHINE DISCHARGE VACUUM PICK-UP
For the discharge of either coolant filtration units, or the machine tool itself, a vacuum collection system can be used to collect, condition and transport the chips/solids for processing downstream in the plant. WATCH MOVIE
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| CENTRAL VACUUM COLLECTION
Once the various collection points are gathered, a central vacuum system brings the streams to the receivers and exhausts the small amount of air required to transport the solids. From the discharge points they can be conveyed into containers, or storage units such as a silo.
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| CENTRAL STORAGE-INTELLIGENT SILO
An other option, one preferred by more and more companies where the stream has a high commodity value like Aluminum, Brass or Copper is the use of a central Silo unit. Here the unit can contain and hold the streams, and ensure no contamination takes place, and that the metals will not be stolen over the weekend. Our units can also incorporate load cells and software to ensure accurate loads and payments for the commodity.
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| DRY DUST AND MQL FILTRATION UNITS
A big difference between wet processing, dry and MQL is the stream may have both large and small particulate/chips and the edges can be very sharp. A filtration system like the version shown here contains permanent media designed to filter the entire range of sizes, and also will last 7-10 years without change out and downtime issues.
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