Rotary Transfer Cleaning Systems RT

In order to satisfy steadily increasing requirements for shorter processing times, Zippel has enhanced the classic multi-chamber system -Machines in the RT Series combine innovative technology with efficient cleaning. Integrated robot systems for loading and unloading as well as deburring guarantee results in line with state-of-the art technology, even for work pieces with intricate designs. Equipped with the latest technology in robotics and engineering, this system guarantees the highest possible load factor and can be easily integrated into any production line.

Technical Process

  • Multi-stage cleaning and rinsing processes
  • Optimum quality robot technology
  • Flake deburring up to 1000 bar
  • Integrated medium maintenance system
  • Short cycle times
  • Largely free of extracted air

Optional Components

  • Vacuum drying
  • Cold or hot air drying
  • Water treatment system
  • Automation/conveyer technology

Advantages

  • High positioning accuracy
  • Low water consumption
  • Smaller space required due to compact design
  • Fully operational even when individual chambers are deactivated
  • Low servicing costs due to anti-twist snap closure on the nozzle line
system example
system example
system example

The individual treatment chambers are situated atop the rotating turntable. The actual number of chambers depends on the number of treatment steps required for optimum cleaning.

Possible treatment steps

  • Low-pressure cleaning
  • high-pressure flake deburring
  • rinsing
  • flooding
  • vacuum and/or hot-air drying

Even purely mechanical treatment processes such as e.g. brush cleaning or brush deburring are possible. If necessary, the downstream outfeed area may be equipped with an additional cooling tunnel for re-cooling the cleaned workpieces.

Loading & unloading of the workpieces is generally done in the same place. To achieve a high level of positioning accuracy, loading & unloading should ideally be done by a robot or another type of automation solution (e.g. portal). Manual loading is also possible as an alternative. During loading, the goods to be cleaned are automatically fastened in a workpiece carrier inside the chamber and cycled through the individual stations, with the workpieces remaining in the same chamber at all times. That way, the cleaning machine can continue its operation with the remaining chambers even in case of a failure or deactivation of an individual chamber. The cleaning process is carried out while the chamber is closed. The high-pressure cleaning is done via high-pressure nozzles mounted either inside the chamber or to a robot arm. These nozzles are supplied by a high-pressure pump with just the right amount of pressure for the various workpieces.

The robot-supported high-pressure nozzles apply a well-aimed amount of pressure to the workpieces, hence ensuring flake-free results after cleaning. Through optional moving of the workpiece (e.g. rotating, swivelling, positioning, etc.) and/or the robot arm, both the three-dimensional contours of a workpiece and the boreholes can be targeted in a very precise manner. Hence, every little corner of a workpiece is no longer out of reach. Selection of the most suitable drying method depends on the workpiece type and its desired final condition. All process media used in the machine are filtered and recycled, while the degree of filtration is adapted to the required residual dirt level.

Containers

The water necessary for machine operation is normally supplied directly from the customer’s water supply mains and is controlled via filling level sensors. Replenishment of the water and cleaning agent is automatic. If several containers are used simultaneously, water supply is available via cascade pumps at customer request. The media are returned from the process zones via a return line with integrated screen. All media containers are made of stainless steel and heat-insulated.

Nozzle system

A variety of different nozzle systems are used for application of the cleaning media. The system supports pressures ranging from low pressure to high pressure (up to 1,000 bar). The nozzle type and volume flow rate are configured and calculated during the design phase. To ensure optimum maintenance and manageable repair, we generally use nozzle clip systems and the nozzle fittings which are equipped with quick-release fasteners.High-pressure nozzles can also be used for flake deburring, if needed.

Closed circuits

All media present in the machine are filtered and reintroduced into the circuit for an effluent-free machine operation.

Enclosure

The entire machine can be enclosed to reduce noise emissions. Large-surface doors will be integrated to ensure adequate accessibility for maintenance and inspection works.

Floor trough

An integrated floor trough is used to ensure collection of the fluids in case of a container leakage. In larger-sized machines, the floor trough is integrated in the machine’s supporting frame. The floor trough is made of rust-free stainless steel and equipped with a leakage warning probe. The collecting volume is at least identical to the volume of the largest container. That way, the provisions of Article 19 I of the Federal Water Act will be met.

Drying

There are a number of different systems available for workpiece drying. Normally, side channel blowers or high-pressure fans are used for this purpose. These fans are designed specifically for the required volume flow rates and pressure rates and are adapted to the specified requirements. The air is applied to the workpieces either by a specially developed blasting pipe system (capillary system with air heating) and/or blasting fan. Air heaters may be used to increase the temperature. Another available drying method involves the use of infrared rays to heat the workpieces and evaporate the residual moisture. The use of a vacuum drying is also possible. However, the parts to be cleaned must have a certain weight in order to be able to store the energy during the washing process and to release it during the vacuum drying in form of evaporation enthalpy.

Bath care

You can download futher information for this at Periphery.

To achieve maximum service life for washing liquids, the washing media are filtered in many different ways. Coarse dirt is separated during a first phase while the medium is returned to the tank. Further residue is separated during full flow by an adequately designed fine-mesh filter. This process involves double filter systems which can be switched over manually to allow filter changes during ongoing operation. This equipment is standard in every Zippel cleaning system. For special needs, additional bath care systems are available as full-flow or bypass systems, including e.g. screen inserts, band filters, swarf conveyors, solenoid separators, three-phase centrifuges, evaporators, osmosis systems, etc. For oil separation, we recommend our proprietary, highly-effective ECOSEP gravity oil separator which works through coalescing action. It separates the oil, passes it into a separate tank, and returns the cleaned water into the container. Even physical water treatment is possible with this system.

The increase in environmental protection requirements for industrial enterprises is the reason behind our search for environmentally-friendly methods for preventing air and water pollution. Over the last 40 years many of Zippel‘s innovations have been awarded prizes and have redefined standards for water and air treatment. Such inventions combine ecology with economy in an exemplary way since they minimise current costs for energy, waste and recycling.

Our systems usually operate within closed loop systems in all medium-conducting sectors. The closed loop does not channel wastewater out of the machine, rather it feeds it back in after it has been filtered. In order to lower the costs for disposal of solid waste and reduce its quantities, there is an option to filter the discharged waste further and discharge it as a concentrate. Zippel has been developing such optimised systems for filtering, exhaust air treatment and water treatment with its suppliers for years. Closed, segregated loop systems are the decisive factor with
regard to operating costs (chemicals consumption, water consumption, energy consumption, heating). In order to increase the efficiency of our machines, we attach great importance to energy-efficient planning and design of components used. As a matter of principle, our cleaning systems are equipped with an integrated base trough (in acc. with para.19 of the German Water Resources Act), including a leakage warning sensor, and therefore do not require a licence from the water authorities.

Environmentally friendly components

  • BioJet: Hydrophysical water and fluid treatment to prevent and reduce the biological contamination of industrial water and process water
  • AquaCorrect: Reduces the surface tension of process water and improves oxygen enrichment
  • EcoSep gravity oil separator: Reduced costs and longer service life thanks to permanent oil separation
  • Water treatment plant
  • ZUT vapour exhaust: Extraction and filtering of water vapours. Recycled fluids are returned to the plant
  • Three-phase centrifuge
  • Filtration and separation technology: A concept custom-designed for the plant in compliance with the most stringent environment requirements, for improved production results
  • Osmosis systems: Compact systems for the desalination of softened potable water
  • Closed fluid and exhaust-air circuits

Technical Data of the RT-5.000-R(H)STVK Cleaning of Gear Casings – Soiled with: Emulsion, Metal Swarf

The RT-5.000-R(H)STVK is a throughfeed cleaning machine with rotary cycle function for cleaning and drying gear casings made aluminium. The chambers are loaded by a robot. After loading, the gear casings are cleaned, rinsed and dried in the cleaning machine and subsequently unloaded again by a robot.

Machine specification incl. roundtable with cooling tunnel – circa values
Length Breadth Height Weight Chambers Cycle time
8.000 mm 4.000 mm 4.200 mm 15 t 5 54 sec/pcs
Temperature of bath Agent Automation Sound level Motor engine roundtable Floor trough - stainless steel § 19 I WHG
40 – 80°C neutral/alcaline 1 Roboter 80 db(A) 3 KW 2 mm
Connections
Water intake Compressed air Electrical
4 – 6 bar, R ¾ “ 3 – 6 bar R ¾ “ 3 phases, 400 V, 60 Hz

Cleaning areas:

low zone | high pressure zone | rinsing zone | vacuum drying zone

Cleaning
Tank capacity Pump Filter
1.500 l 32 m³/h, 4 – 6 bar 50 – 200 μm
Rinsing
Tank capacity Pump Filter
1.500 l 24 m³/h, 2 – 3 bar 15 – 50 μm
Blowing
Blowers    
500 m³ 200 mbar 5 kW – 12 A