Device Description
Equipment dimensions: approximately 8720 (length) x 2700 (width) x 2950 (height) mm
Size of chiller unit: approximately 2200 (length) x 900 (width) x 2000 (height) mm
Technical Requirements
| Cleaning products | Gear parts |
| Capacity requirements | / |
| Beat requirements | 8-10 minutes/basket (time adjustable) |
| Cleanliness requirements | After nitriding, there are no obvious spots on the surface of the parts |
| Cleaning method | Ultrasonic cleaning |
| Heating method | Carbon and hydrogen are indirectly heated by water vapor |
| Standard Basket Size | Square: approximately L800 * W600 * H600mm |
| voltage | AC380V ± 10%, 50Hz, three-phase five wire system |
| control loop | AC220V/DC24V |
| Installed power | Approximately 70kW, actual subject to co signed drawings |
| Average power usage | Approximately 45kW, actual subject to co signed drawings |
| temperature range | 5-40 ℃ |
| relative humidity | ＜ 90% |
Process flow
Loading → Vacuum ultrasonic rough washing → Vacuum ultrasonic fine washing → Steam bath washing+vacuum drying → Steam bath washing+vacuum drying → Unloading
| Number | Process name | Cleaning medium | temperature | processing time | Ultrasonic frequency | Filtering accuracy |
| 1 | Feeding | |||||
| 2 | Vacuum ultrasonic rough cleaning | Hydrocarbon solvent | ≤50℃ | 8~10 minute | 28KHz | 10μm |
| 3 | Vacuum ultrasonic fine washing | Hydrocarbon solvent | ≤50℃ | 8~10 minute | 28KHz | 5μm |
| 4 | Steambath+vacuum drying | Hydrocarbon vapor | ≤100℃ | 15~20 minute | / | / |
| 5 | Steambath+vacuum drying | Hydrocarbon vapor | ≤100℃ | 15~20 minute | / | / |
| 6 | Cutting materials |
Equipment functional structure description
| Number | Name | Describe |
|
1 |
Racks and door panels |
The frame of the rack is welded with carbon steel profiles, and adjustment feet are installed at the bottom;
If there are no restrictions on the transportation path, the equipment will adopt an integrated design; The door panel is made by bending SUS304 sheet metal; The overall appearance is treated with wire drawing/spray coating; Install a transparent observation window on the front side of the equipment. |
|
2 |
Loading and unloading platform |
The material table is driven by an electric motor;
The operator loads the product to be cleaned into a cleaning basket and places it on the feeding mechanism. Press the start button to automatically transport the washing basket to the designated workstation. The robotic arm automatically transports the washing basket to complete the entire cleaning and drying process; The washing basket and workpieces that have been cleaned and dried are automatically transported to the feeding table, and the operator continues to load and clean them after unloading; Install a drain pan at the bottom of the material tray. |
|
3 |
Conveyor mechanism |
The washing basket is transported between processes using a cantilever mechanical arm for independent lifting and lowering;
After conveying each workstation, the robotic arm moves forward/backward/back to its original position; The translation and lifting mechanisms are driven by motors; Confirm the installation of photoelectric sensors on the workpiece lifting and loading mechanism to prevent abnormal damage; Can run automatically and manually; Load capacity of 500kg, including washing basket. |
|
4 |
Vacuum ultrasonic cleaning |
1. Cleaning tank size: approximately 1000 (length) x 800 (width) x 1000 (height) mm, subject to final design;
The inclined design of the groove bottom is conducive to cleaning; The tank body is made of SUS304 stainless steel material with a thickness of 2mm. Insulation cotton is pasted on the outside of the tank body to reduce energy consumption; The ultrasonic vibration plate is arranged at the bottom of the cleaning tank; Install temperature and liquid level detection devices; Each cleaning tank is equipped with a set of circulating filtration system. |
|
5 |
Vacuum drying |
1. Drying tank size: approximately 1000 (length) x 800 (width) x 800 (height) mm, subject to final design;
Configure a vacuum pump to completely dry the parts; The tank body is made of SUS304 stainless steel material with a thickness of 10mm. Insulation cotton is pasted on the outside of the tank body to reduce energy consumption; Before vacuum drying, steam bath washing can effectively improve the cleaning effect of the product and quickly provide the surface temperature of the product, which is conducive to rapid drying of the product. |
|
6 |
Cleaning basket |
Using SUS304 stainless steel material, the size of the washing basket is approximately L800 * W600 * H600mm, subject to the final design;
Quantity provided: 6. |
| 7 | Pneumatic control system | Adopting SMC/Yadeke brand pneumatic components;
The main intake is equipped with a pressure sensor and filter, which automatically alarms when the air pressure is below the set value. |
|
8 |
Electric control system |
Adopting Siemens brand PLC and HMI control system;
Equipment parameters (such as temperature, pressure, process time, etc.) can be set on the HMI; Install emergency stop buttons at manual loading and unloading points and on HMI; All body wiring adopts cable trays and cable trays; HMI is equipped with three-level password protection (administrator, engineer, operator); The running status of equipment components is dynamically displayed on the HMI, and it is easy to operate on the manual operation screen; Install indicator lights (three color lights) on the top of the device to display the operating status of the device: A. Green light: The equipment is operating normally B. Yellow light: equipment idle or other C. Red light: Equipment abnormality or malfunction |
Equipment General Standard Description
The equipment cleaning section is designed as a fully enclosed structure with an exhaust outlet;
The cleaning process is fully automatic and has automatic/manual functions;
The cleaning time can be automatically controlled and adjustable;
All circulation pumps, fans, and motors are marked with the direction of rotation;
The equipment has emergency shutdown and abnormal alarm devices;
All valves are marked with normally open and normally closed markings, and all pipelines are marked with arrows indicating the direction of liquid flow;
Welding processes should be used as much as possible for pipelines, and flange connections should only be used for the convenience of machine maintenance and transportation;
Each tank is equipped with a drainage port, which is equipped with a detachable anti blocking net to prevent small parts from falling off and entering the pipeline to block it;
Equipment installation with movable doors facilitates quick and easy maintenance of components such as pipelines, filters, pumps, heaters, etc., ensuring production needs;
Control the program to set password lock to prevent unauthorized personnel from unintentionally modifying device parameter values;
The equipment is designed as a fully enclosed mechanism, with sound-absorbing cotton attached to the outer door panels (except for the top sealing panel) to reduce noise;
There is a low liquid level alarm and interlock function in the corresponding tank;
The equipment has a good grounding device.
Equipment safety instructions
Equipment operation should be strictly carried out in accordance with the operating manual, and maintenance personnel should receive specialized training;
Parts that may cause harm to the human body shall have clear warning signs on the equipment;
The professional operation section has clear warning signs on the equipment;
Special parts have clear operating procedures.
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