A new multi-chamber system for aqueous ultrasonic cleaning at Fraunhofer FEP will offer flexible cleaning options for industrial component cleaning in the future. This system complements the LinTR learning laboratory, which was developed under the direction of the Fraunhofer FEP together with the Fraunhofer Institutes IPA, IWS and IVV Dresden.
The learning lab offers a comprehensive, modular training concept for industrial parts cleaning for a wide range of requirements and, for the first time, the opportunity to train complex cleaning processes in an extended laboratory environment.
Fighting dirt
The proverbial sand in the gears can bring entire systems to a standstill. Even the smallest particle impurities or filmy residual dirt in process chains are often enough to cause functional restrictions or entire system damage to assemblies. It is therefore necessary to consider the entire process chain with regard to cleanliness requirements. The cleanliness of the production environment and any necessary cleaning processes are crucial for achieving the quality requirements of a component to be produced. Cleaning processes are therefore of quality-determining importance. In addition, there are many dependencies between the process steps, upstream and downstream processes, which can also have complex influences on the cleanliness of the entire process chain.
As is so often the case, it is not just theoretical knowledge that counts in the areas of cleaning and quality assurance; the practical handling of cleaning technology and measuring and testing equipment in particular requires training in the mastery of complex process chains with regard to parts cleanliness. This is precisely where the new learning laboratory for industrial parts cleaning - LinTR - comes in. Funded by the Fraunhofer Academy, Fraunhofer IPA, Fraunhofer IVV Dresden and Fraunhofer IWS are working under the direction of Fraunhofer FEP to design and implement the expanded training opportunities. These should not only include the upgrading of technical possibilities, but also offer a modular, flexible concept and cooperating learning locations.
Modular training concept
Instead of theoretically sequenced learning units, new methodological and didactic concepts are to be used in the LinTR learning lab. The aim is to subordinate all learning units to the process chain approach and to offer the appropriate practical training units. Participants can thus be introduced to technical and logistical interrelationships at the interfaces of the process chain. In addition, the fundamental importance of interdisciplinary communication for ensuring component cleanliness at all points in the process chain is conveyed, which in many cases reveals unrecognized weak points and leads to simple solutions to problems. The good old discussions at the central coffee machine send their regards here.
A modular concept was developed in order to be able to respond to the different time budgets of future learners. The training can be designed so flexibly that a three-day compact seminar or an in-service qualification can be booked. Laboratories at all four project partners are available for practical skills training. Depending on the scope, live video connection or direct use on site is offered.
Cleaning process in practical application during the training course on industrial parts cleaning - Photo: Fraunhofer Cleaning Division
Cleaning system for aqueous ultrasonic cleaning
At the same time, as part of the LinTR project at the Fraunhofer FEP, the existing cleaning technology was expanded to include a multi-chamber cleaning system for aqueous ultrasonic cleaning. The pilot-scale system has a capacity of 100 liters per tank and, in contrast to many conventional ultrasonic cleaning systems, is characterized by the possibility of flexibly controllable process parameters. This is made possible by the targeted control of individual ultrasonic generators. This allows the direction, frequency and power of the ultrasound and therefore the cleaning effect to be controlled over a wide range. In this way, cleaning processes can be precisely adjusted to a wide variety of contaminants and components. The sequence of cleaning steps in the six basins can also be freely adjusted via an automatic system.
This wide range of variations will also be used in the LinTR learning laboratory in future. The theoretical content learned in the training courses is applied didactically and effectively to various cleaning processes and test methods. A special two-part test component was developed for this purpose, which contains typical geometries and materials of industrial components, such as various drill holes, edges and screw connections as well as material combinations of metal, plastic and additively manufactured components. The flexibility of the system's individual control variables allows participants to practice and optimize the cleaning processes until the impurities are removed from the test component with optimal settings.
The cleaning task consists of a defined model contamination on the standard component. For this purpose, typical production-relevant contaminants (lubricating oil, cooling lubricants and grinding pastes) are applied to the component in a standardized manner and then processed using various methods. During the training, participants have the opportunity to find a satisfactory solution to the cleaning task by varying the process parameters. The standardized initial conditions then enable a comparative analysis of the different processes and show the limits and possibilities of the methods using practical examples. A final analysis of the components is also an integral part of the practical activity.
The multi-chamber cleaning system will be put into operation by the end of the LinTR learning laboratory project this fall and should then be available for the first practical cleaning processes by the end of the year. In addition, from fall 2024, the four project partners of the learning lab will have a complete modular system for further training in industrial component cleaning, which is precisely tailored to the requirements of manufacturing companies and offers practical training units at existing laboratories for the first time.
