Hydraulic and pneumatic system components, engine blocks, pump and valve housings, nozzles, transmission parts, steering and brake elements, and other mechatronic components – these are just some examples of parts subject to ever more stringent specifications regarding deburring and technical cleanliness. Formerly, meeting both requirements in an optimum manner called for the use of equipment from diverse manufacturers. Now, with its EcoCvelox concept, Ecoclean has developed a modular solution that combines 5-axis high-pressure deburring with various part cleaning and drying processes in an efficient and space-saving manner. A combination with other products from Ecoclean, such as solvent cleaning prior to deburring in applications involving high oil drag-in, is also possible.
The diverse standard modules of EcoCvelox are rated for parts measuring 200 by 200 by 200 mm that are supplied on pallets. Tooling configuration for the various processes is adaptable to specific parts. Thus, high-pressure deburring can be performed using the standard single spindle at up to 1,000 bar pressure (or a maximum of 3,000 bar should the need arise). An optional HP turret accommodating up to five different tools supports complex deburring operations, providing a tool-to-tool changeover time of only 1.5 seconds. The tools for the spindle and the HP turret can be custom-designed to match the given part, and can be made by 3D printing. For part cleaning, the processes of injection flood washing, spray cleaning and selective rinsing are available, and can be combined. Drying can be achieved by high-velocity air blow-off and/or vacuum.
A novelty in deburring systems, although a common feature on today's CNC machine tools, is the CADCAM interface, which allows the transfer of part design data for the purposes of programming. This can be performed offline to load the data into the machine controller, which is easier and faster than any conventional teach-in method. Moreover, this capability helps to set up deburring processes for new components in minimum time and at low cost. For part identification, a camera system can be integrated.
Part handling for the deburring process takes place in one Y axis in the basic version. However, for high throughput and the associated exacting cycle time requirements, the module can be fitted with a second Y axis. This allows loading and unloading to proceed in parallel with deburring. At 14.5 seconds, the process time thus becomes almost equivalent to the 15-second cycle duration. The same can be achieved for the cleaning and drying module by integrating a second, concurrently operating work chamber.
Pallets are moved between the individual processing stations by means of a linear-drive system, integrated as standard, which is characterised by its dynamic performance and wear-free motor. The system conveys parts from one station to the next at a speed of 4 to 5 m/s, contributing further to operating efficiency. Loading processes can be automated by means of a gantry system or robot.
For process-inherent reasons, all deburring tools are subject to wear, which in turn results in a pressure drop. This effect means that tools need to be replaced after a certain number of operating hours. On the EcoCvelox, patented software and a VFD-controlled high-pressure pump ensure that the process pressure is readjusted accordingly, extending tool life by at least 50%.
For a fast and efficient tool change, the deburring module has a lateral maintenance door that provides easy access to the lance of the single-spindle and turret-mounted high-pressure tools.
As the digital documentation is integrated into the 19” HMI, it suffices to touch the image of the respective module briefly on the screen to view a process technology diagram, flow diagram or electrical circuit diagram in which all installed components are shown, with any ‘malfunctioning’ components highlighted in a different colour. A detailed view of this item can in turn be pulled up at the touch of a finger. Various functions, such as activating or deactivating this component, not merely support intuitive troubleshooting, but supply clear problem-solving information. Moreover, the lists of wear parts and spare parts featuring in the digital documentation will facilitate component ordering, if necessary.
To avoid exhaust air, the system can be optionally equipped with an energy-efficient air recirculation system.