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I. Main Technical Parameter:
1. The model: DYCS400-III
2. Name: Pass through type ultrasonic parts washing machine
3. Workpieces: Aluminum pipes
4. Cleaning medium: Water + Cleaning agent
5. The output: 240 pieces/hour ( double pipes, 2 pieces/ min; single pipe, 4 pieces/ min )
6. Transporting mesh belt width: 400mm
7. Passing height: 180mm
8. Loading height: 950mm
9. Cleaning workpieces mode: Continuous ultrasonic cleaning
10. The conveying speed: 0.15-0.5 meter/min
11. Ultrasonic power: 3000W, Frequency: 28KHz
12. Oil-water separator power: 0.025KW x 2 = 0.05KW
13. Spray water pump: Q = 12.5m3/h, H = 32m, N = 2.2KW x 4
14. Ultrasonic circulating water pump: Q = 6.3 m3/, H= 20m, N = 1.5 KW x 4
15. Spray water tank electrical heating: Power 7 KW x 3 x 2 = 42KW
16. Ultrasonic water tank1 electrical heating: Power 10 KW x 3 = 30 KW
17. Ultrasonic water tank2 electrical heating: Power 7KW x 6 = 42KW
18. Hot air drying heating pipe: 2.2KW x 9KW = 22.5KW
19. Fog suction fan power: 0.37KW x 2 = 0.74KW
20. Circulating hot air fan power: 1.1KW
21. Conveyor gear motor power: 1.1KW
22. Total power: about 136.42KW
23. Overall dimension of the machine( Length x Width x Height ): 11960mm x 1800mm x 1840 mm
24. Voltage: 380V/ 3Ph/ 50Hz
II. Introduction and function:
The machine is pass through type ultrasonic parts washing machine, adopts conveying chain transmission structure, uses the water aqua cleaning liquid as the cleaning medium. It can do the cleaning, rinsing, high pressure air drying, hot air drying of the workpiece surface.
III. The process flow:
Loading-----Spray cleaning------Ultrasonic cleaning-----Ultrasonic rinsing--------Spray rinsing-----Compressed air blow water -------Hot air circulation drying------Unloading.
IV. Working process of the machine:
The robot put the workpieces on the conveyor of cleaning machine at the loading area ( double pipe workpieces, load 2 pieces one time; one pieces, load 4 pieces one time ). Conveyor belt bring the workpieces into the cleaning machine. First enter into spray cleaning to wash the workpieces. Then enter into ultrasonic cleaning. The lower part of the conveying mesh belt is set with an ultrasonic transducer. The workpiece passes through the ultrasonic area, due to the cavitation effect of ultrasonic. To achieve the purpose of cleaning the workpieces. Transport the workpieces after ultrasonic cleaning into the ultrasonic rinsing to reclean the workpieces. Then workpieces enter into spray rinsing area. Then enter into the liquid take off area. The area adopts compressed air to remove the water on the surface of workpieces. The workpieces after remove the water enter drying area to dry. The area adopts finned heat exchanger and large air circulation fan. The device can dry the workpiece at low temperature area. Then unload the workpieces, and finish the whole working process.
V. The Working principle of the washing machine:
1. Cleaning principle:
1.1 Ultrasonic cleaning principle: The high frequency oscillation signal issued by the ultrasonic generator, through the transducer change into high-frequency mechanical oscillation and spread to the media - the corresponding cleaning solvent. Ultrasonic radiation in the cleaning solution forward, Liquid flow produces tens of thousands of tiny bubbles. These bubbles are formed and grow in the negative pressure region formed by ultrasonic longitudinal propagation, and quick closed in the positive pressure area. In the process of what is known as the "cavitation" effect. Bubble closure can form an instantaneous high pressure of more than 1000 atmospheric pressure, like a series of “ small explosions" . Constantly impact the surface of workpieces. So that the dirt on surface and in cracks quickly peeled off. So as to achieve the purpose of surface purification.
1.2 High pressure spraying principle: Oil contamination on the surface of the workpiece being cleaned. In the thermal and metal detergents of the physical and chemical forces and cleaning machine jet water under the action of mechanical force. Make it wet, soften, separate. By the impact of the liquid in the workpiece surface to produce the normal force and tangential force to cause the dirty layer to be broken, stripping, fall off. nWhen the cleaning fluid flows along the workpiece, the dirt particles are removed, so as to achieve the purpose of cleaning. This equipment combines the principle of ultrasonic cleaning and spray cleaning. To make the work to be cleaned thoroughly.
VI. The structure and composed devices:
The equipment mainly consists of: machine frame, upper cover, spaying system, water tank system, ultrasonic tank, generator, transducer, conveying system, filtration system, dewatering system ( liquid removal system), fog suction system, hot air drying system, electric control cabinet, and so on.
1. Machine frame and upper cover
Using frame structure, the frame is made of stainless steel frame square tube, sealing plate with stainless steel, the cover can be used with detachable design, easy to clean the internal adjustment and maintenance of the machine, made of stainless steel plate to produce by edgefold, the appearance of the machine is smooth. A stainless steel water receiving groove is arranged under the body of the cleaning machine.
2. Spray cleaning system
Spray cleaning system is composed of stainless steel submerged pump, spray pipes, drip sink, nozzles and so on. In the cleaning chamber is provided with multi rings nozzles. On the spray pipes are installed nozzles. Nozzles are spherical, can adjust injection angle. So as to achieve the purpose of cleaning the workpieces. Water pump pressure is adjustable. ( The spray pipes, drip sink, spray nozzles are made of stainless steel. Adopt double pump system, one standby and one use, manual valve control. A fixed pump is installed on one side of the water tank, and all connecting pipes are stainless steel. ).
3. Water tank system
The water tank system is composed of a water tank body, a heating device, a digital display temperature control system, an oil-water separation device and a liquid level control system.
3.1 Water tank body
In order to save energy in the use of equipment, the water tank is designed into a double layer insulation structure, the middle is the aluminum silicate insulation material, the inner and outer layers are welded with SUS304 stainless steel plate. The water tank cover is a water seal structure (to prevent the fog from overflowing). The bottom of the tank is designed into a certain slant. Easy to remove the stagnant water in the tank. In addition, the water tank is provided with a water inlet, a water outlet, an overflow port, a sewage outlet, and so on.
3.2 Heating system
The heating system uses electric heating to heat the cleaning liquid, and the electric heating are electric heating pipe for water in cleaning and rinsing tanks, and the water heating pipes are used for heating the cleaning liquid.
3.3 Temperature control system
The machine adopts digital display temperature controller to control the temperature of the cleaning liquid. The cleaning liquid temperature can be adjusted continuously at room temperature up to 60 degree C (the user can set it according to the actual situation). When the temperature of the cleaning liquid reaches the set value, the heater is switched off automatically. When the temperature of the cleaning liquid is lower than the setting value, the heating pipe is automatically opened.
3.4 Belt type oil separator
The workpiece in the cleaning process, the oil on surface are brought into the water tank cleaning liquid, not only affect the cleaning effect, but also shorten the cleaning liquid use cycle. The machine is equipped with a belt type oil separator device in the ultrasonic cleaning tank. The device can effectively remove the floating oil on the surface of liquid tank, can effectively and automatically remove the float oil in cleaning fluid.
3.5 Liquid level controller
Adopt float ball type liquid level controller, can clearly observe the level of the tank level, but also automatically shut down and alarm, when the tank in the clear, rinse liquid level below the set value.
3.6 Filtration system
A three-stage filter is arranged in the cleaning water tank. The first stage is the frame filter box in the reflux port. Filter mesh made of 80 mesh stainless steel. The second stage is the inserting plate type filter box before the pump suction port, made of 100 mesh stainless steel filter. The third stage is the stainless steel bag type fine filter. Rinsing filtration purification process: Liquid return→ The filter box → Insert plate filter → Rinsing water pump → Bag type fine filter ( 20、10um)→ Liquid return. Ultrasonic cleaning filtration purification process: Liquid return → The filter box → Water oil separator → Insert plate filter→ Cleaning water pump → Bag type fine filter ( 40、30um )→ Liquid return.
4. Ultrasonic cleaning tank
This part is composed of an ultrasonic groove, an ultrasonic transducer, an ultrasonic generator, a circulating filter tank, and so on.
4.1 Ultrasonic groove
It is made of stainless steel plate.
4.2 Ultrasonic transducer
The workpieces are transported down into the ultrasonic cleaning area. An ultrasonic transducer is arranged below the conveying mesh belt. The workpiece passes through the upper part of the ultrasonic area. Precision cleaning of workpieces by ultrasonic. The ultrasonic cleaning tank is designed with inclined plane, easy to remove the greasy dirt.
4.3 Ultrasonic generation source
The device is equipped with three ultrasonic generation source, set on a separate cabinet, to control the power of the ultrasonic transducer.
4.4 Ultrasonic
The equipment adopts PT series computer ultrasonic generator. It uses the German SIEMENS semiconductor IGBT power module as the power output primary. Use original Japanese Fuji Electric IGBT protection circuit to promote EX841. Using single-chip centralized control of ultrasonic generator, constant power output. The transducer is made of 721 lead zirconate titanate piezoelectric ceramics. Ensure the service life and reliability of the equipment.
5. Transmission system
It is composed of stainless steel punching mesh belt, transmission chain, conveying speed reducer, motor, transmission shaft and so on. The parts are placed on the conveyor belt at an angle, the conveyor belt hold the parts to get into the cleaning station. Adopt cycloid pin gear reducer drive. Conveying workpieces by a conveyor chain. The transmission speed adopt frequency conversion to adjust. The conveying mesh belt set antiskid strip, easy the workpieces to go up and down. Mesh belt side add baffle, to prevent workpieces to fall.
6. Tension system
Adopt manual tension system.
7. Removal of water
After spray rinsing, the workpieces are transported into the compressed air area to remove the water. The spray pipes in this area can remove the water of workpieces and the conveying mesh belt.
8. Fog suction system
A large amount of water vapor is produced in the process of heating and spraying of the cleaning liquid and rising liquid. Water vapor overflow will affect the environment and operators. Therefore, the steam must be discharged from the cleaning machine. The system through the fan ventilation, then discharge the steam by the pipes.
9. Hot air drying system
Adopt electric heating and hot air circulation, in order to meet the requirements of drying. Through hot air fan to form hot air circulation. So that the drying temperature of the drying room is balance. To achieve the ideal drying effect. Drying temperature continuously adjustable. ( Users can set the temperature according to the actual situation of the workpieces. When the temperature reaches the upper limit of the set value, break off contactor. Heater stop heating. When the temperature is lower than the lower limit of the set value, contactor is connected. Start heating. In order to control the temperature of the drying room. The system is equipped with temperature control device. The device is composed of a thermal resistor and a digital temperature control meter. Automatic control the temperature. Heating adopt fin type heat exchanger. So that the drying area heating rate greatly accelerated. Can heat from room temperature to 70 degrees C ( Temperature adjustable).
10. Electric control system
The machine is composed of an electric cabinet, an operating button box, low voltage electrical components, cables, etc. With manual, automatic two modes of operation. Whether manual or automatic operation has a perfect protection function. Low voltage electrical components selected domestic quality products. The main low voltage electrical components selected Schneider Inc products. The loading end is provided with an emergency stop button. The electric cabinet is set separately, after plastic spraying.
I. Main Technical Parameter:
1. The model: DYCS400-III
2. Name: Pass through type ultrasonic parts washing machine
3. Workpieces: Aluminum pipes
4. Cleaning medium: Water + Cleaning agent
5. The output: 240 pieces/hour ( double pipes, 2 pieces/ min; single pipe, 4 pieces/ min )
6. Transporting mesh belt width: 400mm
7. Passing height: 180mm
8. Loading height: 950mm
9. Cleaning workpieces mode: Continuous ultrasonic cleaning
10. The conveying speed: 0.15-0.5 meter/min
11. Ultrasonic power: 3000W, Frequency: 28KHz
12. Oil-water separator power: 0.025KW x 2 = 0.05KW
13. Spray water pump: Q = 12.5m3/h, H = 32m, N = 2.2KW x 4
14. Ultrasonic circulating water pump: Q = 6.3 m3/, H= 20m, N = 1.5 KW x 4
15. Spray water tank electrical heating: Power 7 KW x 3 x 2 = 42KW
16. Ultrasonic water tank1 electrical heating: Power 10 KW x 3 = 30 KW
17. Ultrasonic water tank2 electrical heating: Power 7KW x 6 = 42KW
18. Hot air drying heating pipe: 2.2KW x 9KW = 22.5KW
19. Fog suction fan power: 0.37KW x 2 = 0.74KW
20. Circulating hot air fan power: 1.1KW
21. Conveyor gear motor power: 1.1KW
22. Total power: about 136.42KW
23. Overall dimension of the machine( Length x Width x Height ): 11960mm x 1800mm x 1840 mm
24. Voltage: 380V/ 3Ph/ 50Hz
II. Introduction and function:
The machine is pass through type ultrasonic parts washing machine, adopts conveying chain transmission structure, uses the water aqua cleaning liquid as the cleaning medium. It can do the cleaning, rinsing, high pressure air drying, hot air drying of the workpiece surface.
III. The process flow:
Loading-----Spray cleaning------Ultrasonic cleaning-----Ultrasonic rinsing--------Spray rinsing-----Compressed air blow water -------Hot air circulation drying------Unloading.
IV. Working process of the machine:
The robot put the workpieces on the conveyor of cleaning machine at the loading area ( double pipe workpieces, load 2 pieces one time; one pieces, load 4 pieces one time ). Conveyor belt bring the workpieces into the cleaning machine. First enter into spray cleaning to wash the workpieces. Then enter into ultrasonic cleaning. The lower part of the conveying mesh belt is set with an ultrasonic transducer. The workpiece passes through the ultrasonic area, due to the cavitation effect of ultrasonic. To achieve the purpose of cleaning the workpieces. Transport the workpieces after ultrasonic cleaning into the ultrasonic rinsing to reclean the workpieces. Then workpieces enter into spray rinsing area. Then enter into the liquid take off area. The area adopts compressed air to remove the water on the surface of workpieces. The workpieces after remove the water enter drying area to dry. The area adopts finned heat exchanger and large air circulation fan. The device can dry the workpiece at low temperature area. Then unload the workpieces, and finish the whole working process.
V. The Working principle of the washing machine:
1. Cleaning principle:
1.1 Ultrasonic cleaning principle: The high frequency oscillation signal issued by the ultrasonic generator, through the transducer change into high-frequency mechanical oscillation and spread to the media - the corresponding cleaning solvent. Ultrasonic radiation in the cleaning solution forward, Liquid flow produces tens of thousands of tiny bubbles. These bubbles are formed and grow in the negative pressure region formed by ultrasonic longitudinal propagation, and quick closed in the positive pressure area. In the process of what is known as the "cavitation" effect. Bubble closure can form an instantaneous high pressure of more than 1000 atmospheric pressure, like a series of “ small explosions" . Constantly impact the surface of workpieces. So that the dirt on surface and in cracks quickly peeled off. So as to achieve the purpose of surface purification.
1.2 High pressure spraying principle: Oil contamination on the surface of the workpiece being cleaned. In the thermal and metal detergents of the physical and chemical forces and cleaning machine jet water under the action of mechanical force. Make it wet, soften, separate. By the impact of the liquid in the workpiece surface to produce the normal force and tangential force to cause the dirty layer to be broken, stripping, fall off. nWhen the cleaning fluid flows along the workpiece, the dirt particles are removed, so as to achieve the purpose of cleaning. This equipment combines the principle of ultrasonic cleaning and spray cleaning. To make the work to be cleaned thoroughly.
VI. The structure and composed devices:
The equipment mainly consists of: machine frame, upper cover, spaying system, water tank system, ultrasonic tank, generator, transducer, conveying system, filtration system, dewatering system ( liquid removal system), fog suction system, hot air drying system, electric control cabinet, and so on.
1. Machine frame and upper cover
Using frame structure, the frame is made of stainless steel frame square tube, sealing plate with stainless steel, the cover can be used with detachable design, easy to clean the internal adjustment and maintenance of the machine, made of stainless steel plate to produce by edgefold, the appearance of the machine is smooth. A stainless steel water receiving groove is arranged under the body of the cleaning machine.
2. Spray cleaning system
Spray cleaning system is composed of stainless steel submerged pump, spray pipes, drip sink, nozzles and so on. In the cleaning chamber is provided with multi rings nozzles. On the spray pipes are installed nozzles. Nozzles are spherical, can adjust injection angle. So as to achieve the purpose of cleaning the workpieces. Water pump pressure is adjustable. ( The spray pipes, drip sink, spray nozzles are made of stainless steel. Adopt double pump system, one standby and one use, manual valve control. A fixed pump is installed on one side of the water tank, and all connecting pipes are stainless steel. ).
3. Water tank system
The water tank system is composed of a water tank body, a heating device, a digital display temperature control system, an oil-water separation device and a liquid level control system.
3.1 Water tank body
In order to save energy in the use of equipment, the water tank is designed into a double layer insulation structure, the middle is the aluminum silicate insulation material, the inner and outer layers are welded with SUS304 stainless steel plate. The water tank cover is a water seal structure (to prevent the fog from overflowing). The bottom of the tank is designed into a certain slant. Easy to remove the stagnant water in the tank. In addition, the water tank is provided with a water inlet, a water outlet, an overflow port, a sewage outlet, and so on.
3.2 Heating system
The heating system uses electric heating to heat the cleaning liquid, and the electric heating are electric heating pipe for water in cleaning and rinsing tanks, and the water heating pipes are used for heating the cleaning liquid.
3.3 Temperature control system
The machine adopts digital display temperature controller to control the temperature of the cleaning liquid. The cleaning liquid temperature can be adjusted continuously at room temperature up to 60 degree C (the user can set it according to the actual situation). When the temperature of the cleaning liquid reaches the set value, the heater is switched off automatically. When the temperature of the cleaning liquid is lower than the setting value, the heating pipe is automatically opened.
3.4 Belt type oil separator
The workpiece in the cleaning process, the oil on surface are brought into the water tank cleaning liquid, not only affect the cleaning effect, but also shorten the cleaning liquid use cycle. The machine is equipped with a belt type oil separator device in the ultrasonic cleaning tank. The device can effectively remove the floating oil on the surface of liquid tank, can effectively and automatically remove the float oil in cleaning fluid.
3.5 Liquid level controller
Adopt float ball type liquid level controller, can clearly observe the level of the tank level, but also automatically shut down and alarm, when the tank in the clear, rinse liquid level below the set value.
3.6 Filtration system
A three-stage filter is arranged in the cleaning water tank. The first stage is the frame filter box in the reflux port. Filter mesh made of 80 mesh stainless steel. The second stage is the inserting plate type filter box before the pump suction port, made of 100 mesh stainless steel filter. The third stage is the stainless steel bag type fine filter. Rinsing filtration purification process: Liquid return→ The filter box → Insert plate filter → Rinsing water pump → Bag type fine filter ( 20、10um)→ Liquid return. Ultrasonic cleaning filtration purification process: Liquid return → The filter box → Water oil separator → Insert plate filter→ Cleaning water pump → Bag type fine filter ( 40、30um )→ Liquid return.
4. Ultrasonic cleaning tank
This part is composed of an ultrasonic groove, an ultrasonic transducer, an ultrasonic generator, a circulating filter tank, and so on.
4.1 Ultrasonic groove
It is made of stainless steel plate.
4.2 Ultrasonic transducer
The workpieces are transported down into the ultrasonic cleaning area. An ultrasonic transducer is arranged below the conveying mesh belt. The workpiece passes through the upper part of the ultrasonic area. Precision cleaning of workpieces by ultrasonic. The ultrasonic cleaning tank is designed with inclined plane, easy to remove the greasy dirt.
4.3 Ultrasonic generation source
The device is equipped with three ultrasonic generation source, set on a separate cabinet, to control the power of the ultrasonic transducer.
4.4 Ultrasonic
The equipment adopts PT series computer ultrasonic generator. It uses the German SIEMENS semiconductor IGBT power module as the power output primary. Use original Japanese Fuji Electric IGBT protection circuit to promote EX841. Using single-chip centralized control of ultrasonic generator, constant power output. The transducer is made of 721 lead zirconate titanate piezoelectric ceramics. Ensure the service life and reliability of the equipment.
5. Transmission system
It is composed of stainless steel punching mesh belt, transmission chain, conveying speed reducer, motor, transmission shaft and so on. The parts are placed on the conveyor belt at an angle, the conveyor belt hold the parts to get into the cleaning station. Adopt cycloid pin gear reducer drive. Conveying workpieces by a conveyor chain. The transmission speed adopt frequency conversion to adjust. The conveying mesh belt set antiskid strip, easy the workpieces to go up and down. Mesh belt side add baffle, to prevent workpieces to fall.
6. Tension system
Adopt manual tension system.
7. Removal of water
After spray rinsing, the workpieces are transported into the compressed air area to remove the water. The spray pipes in this area can remove the water of workpieces and the conveying mesh belt.
8. Fog suction system
A large amount of water vapor is produced in the process of heating and spraying of the cleaning liquid and rising liquid. Water vapor overflow will affect the environment and operators. Therefore, the steam must be discharged from the cleaning machine. The system through the fan ventilation, then discharge the steam by the pipes.
9. Hot air drying system
Adopt electric heating and hot air circulation, in order to meet the requirements of drying. Through hot air fan to form hot air circulation. So that the drying temperature of the drying room is balance. To achieve the ideal drying effect. Drying temperature continuously adjustable. ( Users can set the temperature according to the actual situation of the workpieces. When the temperature reaches the upper limit of the set value, break off contactor. Heater stop heating. When the temperature is lower than the lower limit of the set value, contactor is connected. Start heating. In order to control the temperature of the drying room. The system is equipped with temperature control device. The device is composed of a thermal resistor and a digital temperature control meter. Automatic control the temperature. Heating adopt fin type heat exchanger. So that the drying area heating rate greatly accelerated. Can heat from room temperature to 70 degrees C ( Temperature adjustable).
10. Electric control system
The machine is composed of an electric cabinet, an operating button box, low voltage electrical components, cables, etc. With manual, automatic two modes of operation. Whether manual or automatic operation has a perfect protection function. Low voltage electrical components selected domestic quality products. The main low voltage electrical components selected Schneider Inc products. The loading end is provided with an emergency stop button. The electric cabinet is set separately, after plastic spraying.
