Cleaning unit removes swarf and machining oil

The components incorporate internal holes and the combination of ultrasonics, agitation and underwater jet spraying delivers outstanding cleaning in a fully automated system, according to Guyson.

This results in a validation to the standard for residual particles counted at five and 15 micron size in a defined volume of liquid.

All Kerry Microclean units are designed for use with safe aqueous cleaning fluids and this four-stage system includes a high-intensity ultrasonic cleaning tank, an immersion rinse tank, high-intensity ultrasonic rinse tank and a warm air drying system.

An Autotrans work transfer system automatically moves the baskets between cleaning stations and is designed to ensure consistent, repeatable quality while increasing throughput.

The Autotrans Major Mk4 transporter integrates with both feed and exit conveyors for a fully automatic operation.

The three cleaning stages each comprise an AISI 316L stainless-steel 52-litre capacity tank with an acid passivated finish.

During cleaning, the component basket is vertically agitated up to 30 times per minute via the Autotrans to provide maximum wash solution movement around and inside the components.

The components are positioned on an inclined cradle inside the basket; this is to hold them at a slight angle as opposed to horizontal, to allow water to naturally drain out of the components.

The initial wash stage has multiple high-efficiency module transducers permanently bonded to the base of the tank.

These are driven by a Guysonic 1kW high-efficiency generator and Primewave controller with automatic tuning and LED bar graph power indication, operating at 36kHz.

The cleaning fluid together with any floating debris is drawn over the weir and the debris is then removed by the action of filtration, the filtered solution is returned to the tank by means of a sparge pipe to aid cleaning.

Liquid level protection ensures that the ultrasonics, heating and filtration are prevented from operating when the liquid in the tank is at a low or high level.

Next is the immersion rinse stage.

This incorporates high-flow underwater jetting, to dislodge any machined swarf or debris from inside of the main bore of the cylinder.

This stage also has a built in weir to separate off floating particles; filtration on this unit consists of a coarse pre-filter and final filter complete with pressure gauge.

This is followed by an ultrasonic rinse stage, also equipped with Guysonic 1kW generator and Primewave controller.

This final rinse stage again incorporates weir facilities to remove any further potential contamination.

When the components are lifted clear of the final rinse, they are repeatedly slowly lifted and lowered through an air-knife blow-off curtain, directed up the barrel of the cylinder.

The Autotrans then moves the basket into the final hot air drying section.

The hot air dry stage is fabricated from AISI 316L stainless steel and clad in high-efficiency thermal insulation and incorporates a pneumatic lid fitted to contain heat and improve the drying efficiency.

This thermostatically controlled electric heated unit is fitted with temperature indicator and timer.

The unit has a maximum temperature of 120C and has recirculating warm air drawn in through the base of the chamber to the centrifugal impellor; it is then compressed and fed to two air outlets mounted midway and to the top of the rear wall of the chamber, converging ducts prior to the outlets increase the air velocity for rapid drying.

The basket is then finally lifted out of the drying stage and deposited on the gravity conveyor tracks of the exit table to await unloading.

Gravity conveyors allow the cleaning system to be fully automated when interfaced with the Autotrans, conveyors are supplied with 'basket present' and 'conveyor full' proximity switches that provide the appropriate signals to the Autotrans.

The entire cleaning unit is housed within a secure safety enclosure and a safety interlocking system only allows personnel within the operating work area while the machine is stationary.

Prospective users of Guyson automated cleaning systems can submit sample components for free feasibility testing to the company's development workshop in Skipton, England.