Deburring, cleaning and drying in one production step is made possible by EcoCvelox from Ecoclean. Ideally, cycle times of just 15 seconds per pallet can be achieved.
The deburring process can take place using the standard single spindle or an optional turret that can be equipped with up to five deburring tools.Components for hydraulic and pneumatic systems, motor, pump and valve housings, nozzles, transmission parts, steering and brake parts as well as other mechatronic components - just a few examples of parts that are subject to increasingly stringent requirements in terms of burr-free finish and technical cleanliness.Until now, systems from different manufacturers were usually required to meet both requirements in the best possible way. With the EcoCvelox system concept, Ecoclean GmbH has developed a modular solution that combines 5-axis high-pressure deburring with various processes for component cleaning and drying in an efficient and space-saving manner. However, the new development not only sets standards in terms of flexibility, but also in terms of the ratio of cycle time to process time, equipment, ease of operation and maintenance as well as system availability.
The modular design enables users to individually configure systems for combined high-pressure deburring and component cleaning and drying from a single source and to expand them according to requirements. A combination with other, possibly already existing products of the system manufacturer, for example solvent cleaning before deburring in the case of high oil ingress, is possible. The various standard EcoCvelox modules are designed for components with dimensions of 200 x 200 x 200 mm, which are fed in on pallets. They therefore cover the majority of applications in general industry.
Flexible thanks to modules and CAD/CAM control
The equipment for the various processes can also be adapted to specific components. For example, high-pressure deburring can be carried out with the standard single spindle and a pressure of up to 1000 bar (up to 3000 bar if required). An optionally available high-pressure turret, which can be equipped with up to five different tools, enables complex deburring operations. Changing from tool to tool takes just 1.5 seconds. The tools for the spindle and the HD turret can be designed specifically for the part and manufactured using 3D printing. Injection flood washing, spray cleaning and targeted rinsing processes are available for component cleaning and can be combined. Drying can be carried out using high-speed blow-off and/or vacuum drying, whereby blow-off drying can also be integrated into a cleaning module.
Deburring processes can be implemented quickly
The workpieces are also cleaned and dried as individual parts. Injection flood washing, spray cleaning and targeted rinsing as well as high-speed blowing and/or vacuum drying processes are available for this purpose.According to the company, the integrable CAD/CAM interface, with which machine tools are usually equipped today, represents a novelty in deburring systems. It enables the data from the part design to be used for programming the high-pressure deburring process. Not only can this be done offline and imported into the system control, it is also simpler and faster than conventional teaching. It also helps to ensure that deburring processes for new components can be implemented in the shortest possible time and with minimal effort. Workpiece recognition can be carried out using an integrated camera system. This means that deburring of parts in batch size 1 can also be carried out effectively and economically.
In the basic version, parts are handled for the deburring process by a Y-axis. For a high throughput and the resulting strict cycle time requirements, the module can be equipped with a second Y-axis. This allows loading and unloading to take place in parallel with machining. As a result, the process time of 14.5 seconds almost corresponds to the cycle time of 15 seconds. This can also be implemented in the cleaning and drying module by integrating a second, parallel working chamber.
The pallets are transported between the individual processing units by a highly dynamic linear system with a wear-free motor, which is integrated as standard. It transports the parts to the next station at a speed of four to five meters per second. This also contributes to the efficient operation of the system.
The system can be loaded automatically using a gantry or robot, or manually.
Software constantly adjusts the process pressure
Due to the nature of the process, all tools used in high-pressure deburring are subject to wear, which causes a drop in pressure. As a result, the tools have to be replaced after a certain number of operating hours. With the new EcoCvelox, patented software and equipping the high-pressure pump with a frequency converter enable the process pressure to be readjusted accordingly. This clever solution for continuously adjusting the high-pressure level extends the service life of the tools by at least 50 percent and therefore also increases system availability.
The deburring module has a side maintenance door for quick and efficient tool changes. Both the lance of the single spindle and the tools of the high-pressure turret are therefore easily accessible.
All installed components are displayed on the screen
On the 19-inch flat screen monitor (HMI) of the new, intuitive operating panel, each module of the system is displayed separately and clearly in a complete overview, similar to a smart phoneThenew, intuitive operator guidance contributes to high process reliability and system availability. Each module of the system is displayed on the 19-inch flat screen monitor (HMI) in a complete overview, similar to a smartphone. If a problem occurs, the display of the relevant module changes color, for example by turning yellow or red. As digital documentation is integrated into the HMI, a brief touch of the relevant module on the touchscreen is sufficient to access a display of the process technology, flow diagram or E-plan, on which all installed components are clearly displayed and the "faulty" component, for example a pump, is highlighted in color. This can then be displayed in detail at the touch of a finger. Various functions, such as switching the component off and on, not only enable quick and intuitive troubleshooting, but also provide clear information on how to solve the problem. In addition, the wear and spare parts lists also integrated into the digital documentation simplify and speed up any necessary parts ordering.
Thanks to its high degree of flexibility in terms of both system configuration and process design, the EcoCvelox efficiently covers all deburring, cleaning and drying requirements from a single source. To avoid exhaust air, the system can be equipped with an energy-efficient air circulation system on request.
