Considering the value of the parts they machine, even many small shops have to consider themselves high-end manufacturing operations, providing the range of finishing and fabricating services that custom manufacturers offer as standard. Among those services, increasingly, is parts cleaning. At IMTS 2014, Dürr Ecoclean will present its new EcoCCore system for solvent-based parts cleaning, which uses non-halogenated hydrocarbons or modified alcohols and an innovative technology for optimized cleaning quality. The same factors contribute to lower costs per part, improved process stability, and energy savings.
The EcoCCore also accomplishes high-speed processing, ease of operation, and reduced space demand — all with an award winning design.
Dürr Ecoclean supplies cleaning technology to automotive manufacturers, their suppliers, and the broader industrial market. Automated installation, as well as assembly and testing, are integrated by the Ecoclean Group.
In machining (as well as metal forming, aerospace and medical equipment manufacturing) — wherever grease/oil-free surfaces must be obtained, solvents are the first-choice part-cleaning medium, but Dürr Ecoclean’s EcoCCore represents a new standard. It is designed for operations with non-halogenated hydrocarbons or modified alcohols under full vacuum conditions.
With state-of-the-art technology and characterized by an impressive standard for basic equipment, including two flood tanks, heat recovery, and full-flow plus bypass filtration capabilities, the EcoCCore addresses demanding requirements for cleaning quality, process reliability, cost and energy efficiency, speed, availability, delivery times and eco-compatibility.
Enhanced Cleaning Quality, Process Reliability
A major step toward improved cleaning quality is the new, preliminary vapor degreasing process: the oil-containing distillate is not passed into the flood tank, as usual, but is directed straight into the distilling system. This minimizes oil deposits in the flood tank and an undesirable contamination of the solvent with oil. The result is an enhanced degreasing performance that will be particularly beneficial with parts to be coated or laser-welded after cleaning.
In addition, the preliminary vapor degreasing step offers advantages under elevated oil input conditions, or when a second flood tank is used for a preservative application.
Also boosting cleaning performance is the ability to use ultrasonic and filtration simultaneously. Here particles are discharged throughout this process cycle, opposed to conventional systems where they can settle at the bottom of the work chamber before being filtered.
To this end the EcoCCore pumps are equipped with variable-frequency drive units and control the volumetric flow rate in such a manner that the ultrasonic system can exert its effect. This efficient and flexible combined filtration system ensures an effective discharge of particles.
Moreover, the unit comes with a frequency-controlled rotary drive for rotation and high-accuracy positioning of parts. A "gentle" operating mode prevents sensitive parts from getting dropped or displaced during start-up or handling operations.
Internal heating elements have been removed from the stainless steel flood tanks. This design change eliminates the potential of particle trap points or chip accumulation therefore reducing risks of re-contamination of parts.
Operating the EcoCCore machine is simple, fast, and safe by the new 7-in. color display based on pictographs. For instance, if a temperature needs to be preset only for the first flood tank, a matching setting for the second tank is then selected automatically. Process tracking and maintenance, too, are rendered intuitive and more convenient by the integrated part visualization system. An optional full visualization capability can be integrated above the control panel.
The work chamber is designed to hold cleaning loads measuring up to 670 x 480 x 400 mm (26.4 x 18.9 x 15.8 in), thereby offering one-third more loading volume than the already established Universam 81C/P system. Throughput can thus be doubled, depending on the basket size. The maximum load weight capacity has likewise been increased by more than 30 percent to 200 kg (440 lb). With a cycle time of less than 8 minutes this provides a significant reduction in per-unit cleaning cost.
High Efficiency, Easy Maintenance
Particular attention has also been paid to high efficiency and ease of maintenance. Thus, for instance, both flood tanks are heated entirely with thermal energy recovered from the distilling circuit. The heat input from the distilling system can be adjusted as needed in multiple stages. As a result, energy is saved on the one hand while on the other, a high throughput will be guaranteed even with high oil input rates. For the discharge of oil, a new process based on jacket heating which is fully independent from the distillation system ensures an optimized and gentle oil removal. As a result, a much broader range of oil grades can be removed in safe and reliable manner.
Moreover, oil encrustation requiring costly and time-consuming cleaning is avoided. Cost savings are also achievable by the new level control system that effectively prevents a carryover of preserving medium, thereby reducing its consumption. Switching from cleaning to preserving mode can be made simply by the push of a button on the operator panel.
The design of this equipment is also innovative with an integral loading system and its all-round enclosure made of safety glass. And, the universal EcoCCore machine requires around 5% percent less floor space than the 81C/P machines. A further benefit is that its top height can be reduced to only 7,39 ft. (2,25 m) by removing just a few components where access to the installation area is difficult.