Category Archives: Cleaning

Dürr Ecoclean supplied its 100th EcoCFlex to a South German automotive manufacturer

In the 100th year of its history, 2016, the BMW Group ordered the 100th EcoCFlex system from Dürr Ecoclean. The anniversary specimen of the flexible robot cell forms part of a three-unit package and has received a special painting. The machines have been serving in a volume production environment at the Steyr engine plant since May 2017.


The custom-painted 100th EcoCFlex system operates in a production line for spark ignition engines at the BMW Group’s Steyr engine plant.

The first EcoCFlex machine for cleaning and deburring engine components went into service at the BMW Group in 2005. Eleven years later, when the company was celebrating the 100th anniversary of its foundation, BMW ordered the 100th cleaning machine of this type as part of a major order. Representing the third generation of Dürr Ecoclean’s flexible robotized cells, this anniversary specimen was launched in production at the Steyr engine plant in early May 2017 along with two other EcoCFlex 3L systems. These cleaning machines are adapted to BMW’s latest specifications for technical cleanliness, replacing the transfer systems previously employed on a production line for petrol engines.

Along with the special painting specified to suit the occasion, the BMW Group opted to order the new EcoCFlex 3L systems with handling technology comprising the Scara manipulator developed by Dürr Ecoclean. This rugged robot was purpose-designed for use in cleaning machines and convinces, among other features, with its innovative control approach. Instead of the separate robot control unit commonly adopted, the EcoCFlex 3L relies on just one single CNC controller to operate both the Scara manipulator and the cleaning machine. This simplifies and accelerates programming, service and maintenance of the overall installation. However, the EcoCFlex 3L sets new standards not only for cleaning quality and ease of operation, but also in terms of energy efficiency.

Dürr Ecoclean is a leading supplier of advanced cleaning technology and surface treatment and activation systems to automotive manufacturers and their tiered suppliers as well as to a broad and diversified industrial market. Dürr Ecoclean’s tailor-made technology enables customers to tap savings potentials, e.g., at the level of per-unit costs, energy demand and cycle times. Dürr Ecoclean currently employs around 800 people at more than 10 sites in eight countries around the globe.

www.durr-ecoclean.com

Dürr Ecoclean: Effective Entry into Aqueous Part Cleaning

At AMB, the international exhibition for metalworking, Dürr Ecoclean will present its EcoCCube, an extremely compact cleaning machine. The small footprint and low weight as well as the complete equipment and ready-to-connect construction enable fast and easy integration of the user-friendly front-loading system into production. The EcoCCube thus provides an optimal access into aqueous spray cleaning.

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Whether parts are machined, stamped or deep-drawn, aqueous component cleaning with alkaline, neutral or acidic media ranks among the most widely employed cleaning technologies in many industries and in remanufacturing. Though, depending on the degree of completion, the downstream process and the specific industry, cleanliness requirements vary. When simpler cleaning tasks or intermediate cleaning have to be performed effectively and efficiently, Dürr Ecoclean’s EcoCCube holds many aces. These include, on the one hand, its space-saving footprint of just 2100 x 1630 x 1855 mm/ 6.90 x 5.35 x 6.10 ft. (length x width x height) and its low weight. The two-stage (washing/rinsing) and ready-to-connect spray unit with hot-air drying can thus be integrated easily and in minimum time into any manufacturing environment. On the other hand, the user-friendly front-loading system with integrated manual loading device convinces with flexibility. Parts soiled with oil and or emulsion can be cleaned as individual or as bulk components. The all-round spray system with four nozzle sets works with a high circulation flow rate, both when cleaning and when rinsing. The cleaning effect of the medium used can additionally be increased through rotation of the parts in the work chamber. Parts drying is performed by hot air circulation without loss of vapour to the environment. The EcoCCube’s freely programmable control system allows for storing 10 programs, thus enabling to clean different components parts-specifically. An intuitive HMI control panel makes the selection and start of the programme in question easy and safe, which contributes to high process reliability.

Efficiency through high throughput and long bath service life
The effective cleaning, rinsing and drying operations enable that up to 12 batches, each with a maximum weight of 80 kg (176 lbs.), can be cleaned per hour. Contaminants brought into the bath are continuously removed from the fluids by an integrated full-stream filtration and an oil skimmer. Thus, a long bath service live is achieved. Moreover, it attains its operating temperature quickly and energy-efficiently due to the optimized dimensions of two standard flood tanks.This in combination with the high throughput results in cost-efficient cleaning processes and helps to reduce costs per unit in manufacturing.

www.durr-ecoclean.com

Cut unit costs with workpiece holders and baskets designed for optimum cleaning

These days, defined cleanliness specifications are common in component production across virtually all sectors. To comply with these specifications, some companies are investing vast sums in systems engineering and process technology. However, one major factor is often not considered: the cleaning basket. This is very critical as the cleaning basket influences effectiveness of the costly process technology significantly, and thus the costs of cleaning.

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By the optimum positioning of components in the workpieces holder critical areas such as specific bore holes and undercuts can be treated specifically.

In most cases, adapting or optimising a cleaning process revolves around systems engineering, process technology and the cleaning media. What tends to be forgotten is that process technology such as ultrasonics, spray jets and cleaning media may only work to best effect on parts to be cleaned when they can reach those parts properly – and it is the cleaning basket used that determines the level of effectiveness. Incorporating baskets and workpiece holders into the considerations at an early stage is therefore worthwhile.

Accessibility from every angle
The optimum cleaning effect is achieved where the workpieces in the basket are easily accessible from all sides for the process technology and the media. To facilitate this, Metallform produces workpiece holders and baskets for bulk parts from stainless steel rounds. In contrast to boxes from perforated sheets that are still often used, these baskets have no enclosed surfaces, corners and edges. Therefore, ultrasonics and spray jets have unfettered access to parts and can take maximum effect. At the same time, the open design ensures an effective exchange of media. On the one hand, removed contaminant is flushed from the basket quickly and can be removed by the filter and the accumulation of contamination in the basket is inhibited. On the other hand, the carry-over of cleaning media is minimised, resulting in longer periods between bath changes and thus improved system availability. In addition an open basket design allows cost savings in the drying process, as the easy accessibility of parts reduces the drying time required.

Optimum adjustment of workpiece holders to parts
Early integration of cleaning baskets also enables these to be adapted effectively to the cleaning machine and the workpieces to be cleaned. One consideration in this context is the optimum positioning of components in the workpiece holder. To achieve this, Metallform uses CAD technology. The optimum positioning of components enables the process technology being used to access critical areas such as specific bore holes and undercuts. In this way, particles and film-like contamination are quickly and reliably removed and the effective, resource-efficient drying of parts is assured. Another design feature is the minimising of contact points between the component and the workpiece holder. This also helps to ensure cleaning of consistent quality within a short time.

Stainless steel for long lifetime and maximum security
Metallform produces all workpiece holders and baskets from stainless steel rounds with electrolytic polished surfaces. With good reason: This high quality, durable material is suitable for all cleaning media and prevents components from being recontaminated by the workpiece holder and baths from being contaminated by corrosion and zinc separation. Aside from the design and material, the workmanship of the cleaning baskets is equally convincing. All joints are completely welded and there are no sharp corners, edges or wire ends that could cause injury.
A basket designed for optimum cleaning may not improve the cleaning machine, but it ensures that process technology (which is generally expensive) can work to maximum effect.

www.metallform.de

Optimised cleaning baskets minimise costly internal logistics

From unfinished parts to assembly and packaging, components undergo many different manufacturing steps; these include mechanical processing, cleaning and inspection. In the process, they are frequently transferred to different containers, which takes up a great deal of time and generates high costs. Cleaning baskets, effectively integrated as part of internal logistics, can eliminate many of these unproductive and costly handling steps.

Cleaning baskets effectively integrated into internal logistic processes achieve high cost savings by reducing unproductive and costly transfer processes.
Cleaning baskets effectively integrated into internal logistic processes achieve high cost savings by reducing unproductive and costly transfer processes.

Today, stringent cleanliness specifications and high requirements in terms of cost effectiveness are key features of modern component production. In virtually all sectors, the demand for solutions that make processes more efficient is correspondingly high. Nevertheless, in many cases, internal logistical procedures are not considered when it comes to optimisation. As a result, components are repeatedly transferred to different baskets/containers for various processes (such as mechanical processing steps, cleaning, testing, joining operations, assembly and packaging). The non-productive time that this generates is highly labour-intensive and extremely costly.

Effective integration of cleaning baskets
To exploit the enormous cost reduction potential, Metallform takes account of the logistics needed for component production as well as criteria relating to parts and cleanliness in the design of its cleaning baskets. This calls for certain questions to be addressed: In which manufacturing steps are parts currently transferred? When does cleaning take place? Which processes are upstream and downstream to cleaning? Can parts be fed into these processes in the cleaning basket? Based on the results, the company specialising in the development and production of efficient cleaning and transport baskets creates the ideal solution. A workpiece holder that reduces transfer processes to the absolute minimum while guaranteeing efficient cleaning processes of consistent quality. This cuts down on costly parts handling while substantially reducing the risk of component damage and re-contamination as a result of handling processes – and not least, the number of transport baskets required is drastically lowered. The workpiece holders can be adapted to the requirements of both manual and automated assembly.

Maximum process reliability and cost effectiveness
Cleaning baskets have to be adjusted to specific demands and designed for one particular part or a family of parts. For part-families, flexible solutions consisting of a universal base frame and interchangeable, part-specific inserts allow the adaptation of the workpiece holders to parts of varying size. Such flexibility also offers advantages if the range of parts changes as only the inserts, which are adapted to the workpiece geometry, need to be replaced.
The alternative is a workpiece holder designed for various components of an assembly. The part receptacles for each component of the assembly are designed on a part-specific basis by the design engineers of the Bretten-based company. This approach has several advantages. Firstly, the worker can determine whether the assembly is complete already when fitting the workpiece holder. Workers also benefit from a continual overview of the stock of required parts, and have the option of controlling production or a Kanban system effectively. Moreover, since all components needed are contained in a single workpiece holder, the space requirement in the assembly area is reduced compared to a non-mixed delivery. As a result, there is no need to waste time collecting parts from numerous baskets or interrupting assembly due to missing parts. This makes assembly not only easier but also more reliable. Depending on the number and size of the components, workpiece holders can be designed for one or more assemblies and adapted to different versions.

www.metallform.de

 

parts2clean attracts record visitor turnout

It may have been only eight months since parts2clean 2013, but parts2clean 2014 served up all the quality and quantity its exhibitors and visitors were hoping for and more. parts2clean 2014 featured 269 (2013: 265) exhibitors from 14 countries. It occupied 6,627 square meters (71,332 sq. ft.) of net exhibition area, up a good four percent compared with 2013.
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In this, its twelfth season, the international trade fair for industrial-parts and surface cleaning was co-located with the O&S international trade fair for surface treatments and coatings for the very first time. Held from 24 to 26 June, the premiere of this double act brought over 10,900 visitors to the Stuttgart Exhibition Center.

Positive synergies
“The resulting synergies were a major plus for the exhibitors and visitors of both parts2clean and O&S,” said Olaf Daebler, the project director in charge of the two fairs at Deutsche Messe. “Sixty-two percent of all O&S visitors also attended parts2clean.” As a result, the post-show visitor statistics for parts2clean indicate that the show attracted no fewer than 8,460 visitors, which is just on 70 percent up on parts2clean 2013. Twenty-one percent of these visitors came from outside Germany, as compared with 20 percent in 2013. In all, 33 countries were represented in their number. The visitor cross-over between the two shows was greeted with enthusiasm by exhibitors.

Quality visitors with decision making authority and firm investment intentions
The gains this year were not purely quantitative. Exhibitors were equally pleased with the high level of technical understanding and decision making authority of the visitors they encountered. In their survey forms, 86 percent of the visitors indicated that they were involved in their organizations’ operational investment decisions, and 51 percent said they were at the show with concrete investment projects in mind.
And it’s clear that the visitors were satisfied with the show’s exhibition offering, given that 94 percent of them said they would recommend parts2clean to others and 60 percent said they already had definite plans to attend again in 2015.

Upcoming surface technology shows by Deutsche Messe
Deutsche Messe’s next surface technology show in Germany is the SurfaceTechnology fair, which is part of the Hannover Messe industrial technology fair that runs from 13 to 17 April 2015. parts2clean is an annual show, whereas O&S is two-yearly, meaning that the next parts2clean show will be a solo affair, running from 9 to 11 June 2015, and the next parts2clean/O&S double act will be held from 31 May to 2 June 2016.
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www.parts2clean.de

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Setting a standard in machine tool maintenance

UK-based Precision Technologies Group (PTG) has totally revised its range of machine tool maintenance and support services, to provide what it believes to be one of the most comprehensive and cost-effective customer care packages available for machine tool users globally.

Absolute Care: Holroyd technicians maintain a TG series grinding machine.
Absolute Care: Holroyd technicians maintain a TG series grinding machine.

Under the name of Absolute Care, the company has created a suite of tailored maintenance solutions for users of its Holroyd ultra-precise milling and grinding machines. A similar range of Absolute Care services is available for owners of PTG Heavy Industries’ Powerstir friction stir welders, and Binns & Berry/Crawford Swift heavy-duty lathes, roll lathes, deep hole boring machines and roll grinding machines.

PTG care for other machine brands
In addition, extensive repair, refurbishment and upgrade services, as well as CNC repair and upgrade solutions, are available for lathes and machine tools from a wide range of other manufacturers.

Ensuring a long and reliable working life
“At Precision Technologies Group, we have always strived to offer the highest levels of machine tool maintenance,” comments Customer Care General Manager, Alan Mead. “In creating our menu of Absolute Care services,” he continues, “we have made it simpler than ever for our customers to select the precise maintenance solutions they require, and ensure their PTG machine tools provide a long and reliable working life. Additionally, by developing a bespoke range of services for owners of other machine tools, we provide the option of having their equipment maintained to the uncompromisingly high standards that Precision Technologies Group is renowned for.”

Absolute Care: the comprehensive solution
The Absolute Care services offered by Precision Technologies Group include emergency UK, EU and worldwide engineer response, remote machine support and fault diagnosis, Planned Preventative Maintenance (PPM), process enhancements, CNC repairs and upgrades, machine refurbishment and reengineering, OEM parts, and a brand new dedicated machine tool care plan.
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Holroyd Precision
Precision Components
Advanced Developments
Customer Care
Harbour Lane North
Milnrow, Rochdale
Lancashire OL16 3LQ UK
T +44 1706 508 616
F +44 1706 353 350
[email protected]
www.holroyd.com

For Europe
PTG Deutschland (Europe)
Pilsener Straße 9
86199 Augsburg
Germany
T +49 821 908983 0
F +49 821 908983 20
[email protected]

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Innovation in water-based parts cleaning

With its EcoCWave, Dürr Ecoclean has developed an innovative equipment system for water-based cleaning processes which can handle a wide range of tasks from coarse to fine cleaning in an efficient manner. To this end, it comes with a list of features which ensure superior cleaning quality and process reliability, shorter idling times, and major energy savings.

Thanks to its design the new EcoCWave does not only meet any cleaning task but also cares for optimized quality and efficiency in cleaning processes.
Thanks to its design the new EcoCWave does not only meet any cleaning task but also cares for optimized quality and efficiency in cleaning processes.

Water-based part cleaning with alkaline, neutral or acidic media ranks among the most widely employed technologies in many industries. Application levels range from coarse to intermediate and, ultimately, fine cleaning. Dürr Ecoclean’s new EcoCWave system, superseding the existing Universal 81W line, covers this entire application spectrum thanks to its modular, forward-looking technology. With its very small footprint the system can easily be integrated in any production process. It also provides versatility, being easily adaptable to changing cleanliness and throughput specifications so that the user will enjoy investment certainty.

Intelligent technology yields superior cleaning quality
The EcoCWave is equipped with two or three flooding tanks, depending on customer specifications. The tanks exhibit a flow-optimized rounded geometry and are of upright design. Unlike the low-mounted rectangular containers used in conventional aqueous cleaning equipment, the round tanks prevent the formation of chip and dirt traps. Improved cleaning quality and a longer service life of the cleaning fluid are the result.

Faster processes cut per-unit costs
Powerful pumps and large-diameter piping used throughout the EcoCWave accelerate the operations of filling and draining the work chamber and tanks. As a result, non-productive times are minimized, product throughput is increased and per-unit cleaning costs are reduced. These improvements benefit spray cleaning processes as well.

Easy operation with process visualization
A new colour display with self-explanatory pictographs makes the EcoCWave easy, fast and reliable to operate. Diverse process data such as the work chamber fluid level are indicated in real time by the built-in process visualization system. An acquisition of all relevant process parameters (e.g., for the development of cleaning programs) can be implemented optionally.
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Dürr Ecoclean GmbH
Rainer Straub, Sales
Tel. +49 711 7006-246
[email protected]
www.durr-ecoclean.com

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