Basic Info.
Model NO.
cleaning machine
Application
Pharmaceutical Cleaning
Cleanliness
Medium Cleanliness
Trademark
cleaning machine
Transport Package
Container
Product Description
1, Cleaning object and parameters
1. Workpiece Name: pipe fittings
2. Material of workpiece: galvanized pipe
3. Weight of workpiece:
4. Workpiece dimension:
5. Cleaning part: outer surface of workpiece
6. Cleaning dirt: iron chips, oil dirt, dust, etc
7. Cleaning medium: water based cleaning solution
8. Cleaning property: cleaning before powder spraying
2, Cleaning process
Feeding → ultrasonic cleaning → blanking
3, Conveying and clamping of workpieces
1. Conveying of workpieces
The chain conveyor belt is used for continuous transportation, that is, the cycloid needle wheel reducer is driven by the motor, which drives the chain conveyor belt to run continuously. The workpiece is transported to ultrasonic station, and its conveying speed is 0.8-2m/min, and it is stepless and continuously adjustable. Adjust the conveying speed of the conveyor belt, and adjust it directly on the frequency converter located in the electric control cabinet.
Frequency of frequency converter (Hz) ten fifteen twenty twenty-five thirty thirty-five forty forty-five fifty
Conveying speed (m/min) zero point eight one one point two one point four one point six one point eight two
The relation table between motor frequency conversion speed regulation and conveyor belt speed
22. 2. Clamping of workpiece
The workpiece is directly suspended on the chain conveyor belt, and positioned by baffle plate. It is transported along with the chain conveyor belt. The loading and unloading of the workpiece are manually operated.
4, Cleaning method of workpiece
During the continuous transportation of workpiece, the ultrasonic cleaning of cleaning solution is completed. When the workpiece is transported to the ultrasonic chamber, when the workpiece is transported to the ultrasonic cleaning tank, the ultrasonic transducer arranged below shall be used to clean the processing surface of the workpiece to remove the dirt on the workpiece.
In order to achieve better cleaning effect, the frequency of ultrasonic wave is 28kHz and the ultrasonic power is 24kw.
1. Principle of ultrasonic cleaning
The principle of ultrasonic cleaning is that the high frequency oscillation signal sent out by ultrasonic generator is transmitted to medium cleaning solvent through the conversion of transducer into high frequency mechanical oscillation. Ultrasonic wave in the cleaning liquid is dense and forward radiated, which makes the liquid flow and produces tens of thousands of micro bubbles. These bubbles form and grow in the negative pressure region of ultrasonic longitudinal propagation, but close rapidly in the positive pressure region. In this process, the bubble closure can form instantaneous high pressure of more than 1000 air pressure, and continuously generate instantaneous high pressure, which is like a series of small "explosions" constantly impacting the surface of the object, so that the dirt in the surface and gap of the object can be peeled off rapidly, so as to achieve the purpose of surface purification of the object.
The mechanism of ultrasonic cleaning is as follows: because of the strong shock wave when cavitation bubble burst, part of the dirt layer is stripped off, dispersed, emulsified and detached under the action of shock wave. The bubbles caused by cavitation, the gap and void between the dirt layer and the surface layer formed by impact permeate. Because of the synchronous expansion and contraction of such small bubbles and sound pressure, the physical force like peeling repeatedly acts on the dirt layer, and the dirt layer is stripped layer by layer, and the bubble continues to penetrate into the inside until the dirt layer is completely stripped. This is the secondary effect of cavitation. The impact of ultrasonic vibration of cleaning fluid on dirt in ultrasonic cleaning. Ultrasonic accelerates the dissolution process of chemical cleaning agent to dirt, and combines chemical force and physical force to accelerate the cleaning process.
It is an effective method to clean workpiece quickly and effectively by using ultrasonic energy. When cleaning, it is put into the cleaning tank. The ultrasonic transducer converts the electrical signal generated by the ultrasonic generator into ultrasonic vibration. At this time, many tiny bubbles will be generated in the cleaning solution. This kind of bubble will form the effect of "ultrasonic cavitation" in the continuous production and closing motion. When the micro bubble is completely closed, it will produce micronucleus wave from the center to the outside, The impact force of thousands of atmospheric pressure can be achieved in an instant, which makes the dirt on the surface of the object peel off to achieve the purpose of cleaning.
2. The cleaning process is as follows
technological process Working temperature (ºC) Cleaning time (min) Preheat time (H) Solvent concentration (%)
ultrasonic cleaning 45-55 2 adjustable 0.5-1 2-5
3. Cleaning form and quantity
technological process form Quantity (piece)
ultrasonic cleaning Ultrasonic transducer twenty-four
7, The main functions of the cleaning machine station and station
There are three stations in the cleaning machine
1 feeding → 2 ultrasonic cleaning → 3 blanking.
1. Feeding and unloading: the upper and lower materials of the workpiece are all operated manually.
2. Ultrasonic cleaning: ultrasonic cleaning is carried out by ultrasonic transducer arranged in the ultrasonic cleaning tank, and the workpiece is cleaned by water agent. Oil, iron chips and other dirt on each surface of the workpiece are removed by thermal and chemical and physical forces.
8, Cleaning and heating of cleaning solution
In order to meet the requirements of the cleanliness of the workpiece, the cleaning and rinsing solution must be purified.
1. Purification of ultrasonic cleaning solution
Cleaning solution → circulating water tank → plate filter screen
↑ ↓
Precision filter ← circulating pump
After the ultrasonic cleaning liquid is filtered by the plug-in screen and precision filter, the filtration accuracy is ≤ 20 μ m. , recyclable.
2. Heating of cleaning solution
In order to achieve a better cleaning effect, the rinse water needs to be heated. The heating is electric heating method, and the heating temperature is 40-60 ºC and can be adjusted automatically.
name Heating form Heating temperature (ºC) Regulation form Heating power (kw)
Ultrasonic cleaning solution Electric heating 45-55 Self control adjustable 21+21
9, Main structure of equipment
The machine is mainly composed of the body and upper cover, conveying system, ultrasonic cleaning system, mist absorption system, oil-water separator and electrical control system.
1. Fuselage and upper cover
It is mainly composed of frame, upper shell and guide water tank to support and install various systems. The upper shell of the washer is a sealed and detachable structure, which is convenient for cleaning the interior of the cleaning room and maintenance of equipment.
1.1. Frame: the frame is welded by stainless steel section steel, which is used to carry the installation of various systems, mechanisms and upper shell. It is welded by square pipe and angle steel made of stainless steel. It is the base frame of equipment, and the frame sealing plate is made of stainless steel wire drawing plate.
1.2. Upper shell: the upper shell mainly refers to cleaning the upper cover, drying the upper cover and cooling the upper cover. The upper cover is made as detachable to facilitate maintenance.
1.3. Guide water tank plate: welded with stainless steel plate, and the cleaning liquid flows out from the lower part of the washer. In order to ensure the smooth flow of liquid, there is a certain inclination at the bottom.
2. Conveying system
The conveying system consists of driving device, conveyor belt, main driven shaft group, frequency converter, emergency stop switch, proximity switch and photoelectric switch.
2.1. Drive device: it is composed of motor, cycloid needle wheel reducer, transmission sprocket group and frequency converter. The power of the motor is 1.5KW, the reduction ratio of cycloid needle wheel reducer is 1:391. The frequency converter is used to speed the speed. The drive sprocket group is composed of sprocket and roller chain.
2.2. Conveyor belt: it consists of stainless steel chain with pitch p=31.75, shaft string and positioning block. The stainless steel chain adopts bending chain, and the chain shaft is stainless steel circle. The positioning bar is installed on the chain to prevent the workpiece from shifting or sliding during ultrasonic cleaning and sinking and rising.
2.4. Main driven shaft group: it consists of sprocket group, main driven shaft, spherical bearing and bearing pedestal. Sprocket group and main driven shaft are made of carbon steel, and heat treatment is strengthened and electroplated.
2.5. Frequency converter: the frequency converter is used to speed the conveyor belt.
2.6 emergency stop switch: emergency stop switch shall be arranged at the equipment loading and unloading position and middle water blowing position to timely handle emergency.
2.7 photoelectric switch: set photoelectric switch at the equipment blanking position to prevent the workpiece from falling off
3. Ultrasonic cleaning system
The ultrasonic cleaning system consists of ultrasonic cleaning tank and ultrasonic transducer
One ultrasonic cleaning tank is set up, and the ultrasonic cleaning tank uses water + metal cleaning agent to carry out ultrasonic cleaning on the workpiece. The tank is composed of ultrasonic cleaning tank, ultrasonic transducer, circulating filtration system, heating device and temperature control device, liquid level controller, sewage device, etc.
3.1 ultrasonic cleaning tank: the groove system is made of ship type, and a DG40 ball valve is set at the bottom of the tank to discharge water. The bottom plate of the tank is inclined to the drain port. At the same time, the tank body is equipped with water inlet, and the tank body is made of 2mm304 stainless steel, and the outer layer is stainless steel plate, and the layer is provided with 40mm thick heat preservation material. Water tank storage capacity: about 1.0m3.
3.2 ultrasonic transducer: made of 321 stainless steel plate, the ultrasonic transducer is placed on the upper and bottom of the tank body, with power of 2kW × 12 +2kw × 12, left and right side are placed 12, working frequency is 28kHz.
The equipment adopts 24 SD-2000 computer ultrasonic generator. The ultrasonic power supply is controlled by single chip microcomputer, the original protection circuit components of Toshiba company and Siemens power devices are in the leading position in China.
The ultrasonic transducer is immersion structure, and sd6850-28h vibrator is adopted. The working surface of ultrasonic transducer is all plated with hard chromium by special technology, which can effectively prolong the service life of the transducer.
3.3. Circulating filter system: outside the ultrasonic cleaning auxiliary tank, the circulating filter pump and precision filter are set. After the cleaning liquid is filtered, it can be recycled.
3.4 heating device: adopt stainless steel electric heating pipe to heat the solution to ensure that the cleaning liquid is within a certain temperature range, and the electric heating pipe is arranged at the lower part of the water tank body, and the protective cover is installed on the heating pipe. At the beginning of work, all heaters are started. After the temperature reaches the specified temperature, one group of heaters stops working and the other group is automatically insulated.
The temperature control instrument of double digital display is used to automatically measure and control the liquid temperature of water tank. The liquid temperature is 40-60 ºC and can be adjusted automatically. The temperature controller is set on the panel of electrical control cabinet, which is convenient to observe and adjust. The temperature resistance is measured and installed at the lower part of the liquid box, and connected with the digital display temperature controller through compensation wire.
3.5. Liquid level control instrument: the floating ball type liquid level controller is used to control the liquid level in the liquid tank to prevent the transducer from being damaged.
3.6. Sewage discharge device; It is composed of blowdown valve and pipeline, through which the sewage and waste residue produced by the cleaner are removed. The blowdown valve is installed on the bottom of the liquid tank of the cleaner, so that the sewage can be completely removed.
4. Mist absorption system
It is composed of centrifugal fan and air inlet, which can prevent a large amount of steam from overflowing from the feed port, affect the working environment and avoid accidents.
4.1. Centrifugal fan: centrifugal fan is adopted to lead hot steam out and exhaust to prevent the overflow of hot steam.
Technical parameters of centrifugal fan: air pressure p=980pa, air volume q=1250m3/h, power is about 0.37kw.
4.2. Air inlet: horn type interface is adopted to fully discharge hot steam.
There are two sets of mist absorption system.
5. Oil water separator
The oil-water separator is set at the upper part of the cleaning liquid tank, and the oil dirt suspended on the upper part of the liquid can be collected and eliminated by the rotation of the reducer through the separator. It is composed of a transmission device, a drum, a mesh belt, an oil scraper plate assembly and a shell.
5.1. Transmission device: it is composed of motor and gear reducer, with power of 0.025kw and reduction ratio of gear reducer being 1:180.
5.2. Drum: it is composed of a drum body and a baffle plate, through which the net belt can rotate at a uniform speed.
5.3. Net belt and oil scraper plate assembly: the net belt adopts oil-resistant PU belt to fully improve the oil bearing effect. The oil scraper assembly is composed of stainless steel plate, adjusting roller and shaft, through which the floating oil on the net belt is scraped off.
5.4. Shell: made of stainless steel, used to fix the deceleration motor.
6. Electrical control system
6.1. The whole machine function adopts "Siemens" PLC to control the whole machine operation, and the main low-voltage appliances are domestic and joint venture brand products.
The installation position of control cabinet is easy to adjust, the control panel button is arranged reasonably, the line layout of control cabinet is clear and the layout is reasonable, and the electrical system has reliable safety protection measures.
6.2. Adopt safe and reliable digital display temperature control instrument to keep the water temperature within a certain temperature range effectively.
6.3. Photoelectric switch at the equipment blanking position to prevent the workpiece from falling off and causing accidents.
6.4. The water shortage alarm protection system is arranged in the rinsing liquid tank. When the water tank is at low water level, the buzzer will alarm and the water pump, ultrasonic wave and transmission system shall be shut down.
6.5 socket and light lamp for convenient equipment inspection and maintenance shall be installed in the control cabinet. When the door of electric cabinet is opened, the light will be automatically lit and will be extinguished automatically after closing the door. The power supply of lighting lamp and maintenance socket is directly taken from the workshop power grid, and is not controlled by the main power switch of the equipment.
10, Main technical parameters
1. Loading height: 950mm
2. Size of feed port: 1400 × 200mm (L × (high)
3. Conveying speed: 0.2-1.2m/min stepless continuous adjustable
4. Ultrasonic source: SD-2000 24 sets
5. Ultrasonic bath liquid temperature: 45-55 ºC self-control adjustable
6. Total power of equipment
(1) Washing machine drive motor; 1.1kw
(2) Ultrasonic power: 48kW
(5) Ultrasonic tank circulating water pump: 0.37 kwx2
(6) Mist suction fan: 0.37kw × two
(7) Oil water separator: 25 W
(8) Electric heating of ultrasonic liquid tank: 21 + 21kw
Total: 92kw
14. Equipment overall dimension: 8000 × two thousand and five hundred × 1600 (long × wide × (high)
