What Is a Parts Washer?
Mechanical parts cleaning machine is a machine that uses ultrasonic waves, organic solvents, etc. to clean parts.
Machine parts washing machine
- Chinese name
- Machine parts washing machine
- Decontamination
- Organic solvents
- work process
- Wash, dry and filter
- Features
- Application of ultrasound
- Mechanical parts cleaning machine is a machine that uses ultrasonic waves, organic solvents, etc. to clean parts.
- The industrial application of organic solvents on the surface of mechanical parts to remove contaminants has a long history. Because domestic solvents such as kerosene and gasoline, which have been phased out in the 1930s and 1940s, are still used as cleaning fluids for mechanical parts, these solvents have great fire hazards and dangers. In addition, gasoline and kerosene cannot be recycled in the process of high consumption and high costs, and will cause environmental problems in the working environment (according to international standards, all organic solvents are not allowed to be directly discharged into the atmosphere), As well as market conditions where customers pay more and more attention to the cleaning quality and importance of mechanical parts, efficient and environmentally friendly cleaning solutions for mechanical parts are becoming more prominent.
- At present in the world, due to the high cleaning effect of organic solvents such as trichloroethylene, tetrachloroethylene, and hydrocarbon solvents, it can widely dissolve the vast majority of pollutants, is highly inclusive, and can be recycled and saved. Excellent performance such as cycle time is widely used in degreasing and cleaning the surface of mechanical parts.
- But at the same time, the discharge of organic solvents will pollute the environment, and excessive inhalation will cause personal injury. In 1993, the European Union completed the legislation on solvent emission standards (EU1999 / 13 / EC Solvent Emissions Directive); this regulation abolished the traditional method of using solvents and solvent vapors to soak in tanks to clean metal parts; With the introduction of the EU s emissions regulations in 1993, there have been devices on the market that tried to use two or more capped devices and recyclable adsorption devices to reduce solvent emissions. Is unsuccessful. Therefore, in 2003, the European Union formulated the more stringent 12921 standard (VOC Directive 2003/87 / EC), which stipulates that the concentration of residual solvent in the cleaning compartment before opening the cleaning compartment door must be less than 1 mg / m? (145 PPM);
- After the formulation of EU standards, the annual consumption of organic solvents such as tetrachloroethylene, trichloroethylene, and hydrocarbon solvents has been reduced by 98%; and the carbon residue on the surface of cleaning parts has always been less than 3-5 mg / m ?.
- In order to reach the preset residual concentration and discharge standard of the solvent, the solvent is continuously distilled and purified by the PLC control system. Therefore, all contaminants are separated in the solvent and then automatically transferred to the residue container. These processes are performed in a fully enclosed solvent management system. Vacuum drying, PPM controller installed in the cleaning cabin, and activated carbon regeneration and recovery device ensure that after cleaning is completed, all unloaded mechanical parts are free of solvent residues.
- Excellent surface cleanliness / negligible air emissions
- The fully enclosed mechanical parts washer guarantees near-zero atmospheric emissions. Recirculated air drying systems and advanced vacuum technology eliminate the use of exhaust flues during the design and installation process. The cleaning effect is the same whether it is in a small cleaning tank with only 450 mm x 300 mm x 200 mm or a very large cleaning tank that can hold several tons of solvent during cleaning:
- Consistent level of surface cleanliness of mechanical parts
- Absolute guarantee of compliance with environmental emission standards
- Good permeability -low surface tension (25-30 dynes / cm, surface tension of water is 72 dynes / cm), which means that liquid can easily enter or exit parts of complex geometry. Just like those tiny threads and contaminants in blind holes can be washed away.
- No chemical residues and extensive inclusion -the solvent is highly tolerant and can dissolve most of various pollutants widely. And after the components cleaned by the solvent are dried, there will be no chemical residue on the surface of the components. Although it is generally believed that water-based surfactants are "species-specific agents" and that these surfactant chemicals are used in a large number of production processes, if these surfactants are not sufficiently rinsed, these are not Volatile chemical residues will bring certain hidden dangers to product quality and safety.
- Clean cleaning quality -In a fully-closed solvent metal cleaning system, an independent distillation system not only ensures a clean solvent after each distillation cycle but also provides a pure solvent vapor, which guarantees a consistent Quality of parts cleaning. Because water-based cleaning technology cannot ensure the recycling and cleanliness of water through the distillation of water, it is mainly achieved through the use of filtering devices and a large amount of water resources.
- Fully dry and safe -the volatility of organic solvents ensures that the drying of mechanical parts is fast and thorough. Just compare the latent heat of water and solvent, because the latent heat of water is 2280kj / kg, and the latent heat of solvent is 200 -300kj / kg. Since the latent heat of water is 10 times that of solvents, it is difficult to completely dry mechanical parts in water-based cleaning. The latent heat of the solvent is only 10% of water, which ensures the fast and efficient cleaning of the solvent and prevents the generation of rust spots.
- Energy saving and high efficiency -due to the application of vacuum technology in the cleaning chamber to reduce the boiling point, the remaining part of the thermal energy in the distillation process ensures instant gasification, which can improve efficiency and reach 10 washing cycles per hour.
- Environmental protection -the biggest disadvantage of organic solvents is air pollution, but after using a fully enclosed cleaning system, these pollutions can be effectively controlled. Similarly, because water-based technologies rely heavily on the use of surfactants, these surface-active chemicals that cannot be fully degraded can cause significant residual pollution of water resources. According to estimates, the pollution of the environment after cleaning-the impact of water pollution is 200-2000 times that of the use of organic solvents.
- The fully enclosed solvent cleaning technology guarantees that all pollutants will be isolated in the distillation box, and we no longer need to think about how to deal with those large amounts of "dirty solvents". In addition, current solvent providers provide specialized solvent transfer systems for closed and safe storage and transportation of solvents and solvent residues.
- Cleaning steps
- High pressure spray cleaning, heating and immersion of solvent at room temperature and ultrasonic vibration-assisted cleaning method. Spray rinsing, immersion and solvent vapor mist process. Optimized fine filtration during rinsing can reach 50 micron. Vacuum suction and hot air Cyclic drying. In addition, special additives can be added for long-term storage to passivate the cleaning parts for a long time (anti-rust treatment for long-term storage).
Machine part cleaning machine cleaning technology
- Hermetically sealed industrial solvent cleaning procedures represent the ideal application technology, with the goal of achieving economical use and consistent cleaning quality for industrial cleaning processes. Chloride solvents, aliphatic hydrocarbon solvents (Class III A) , hydrochlorofluorocarbons, bromide solvents and HFE fluorinated liquids can be used. Although the solvents used have different characteristics, experience has shown that even the most difficult inorganic and organic pollutants to be cleaned can be successfully treated by hot and cold solvent spray soaking and solvent vapor rinsing during the treatment process. Clear. In the subsequent dry phase of the sealed environment (through hot air exchange circulation and vacuum), almost all the solvents in the parts and the system are recovered, and the solvent consumption is almost zero. This solvent system is quite effective, especially for the treatment of parts with complex shapes including blind holes, fine holes, welds, etc., thanks to repeated spraying, dipping and solvent vapor rinsing of the solvent. Solid dirt particles like powder, chips, shavings and inorganic salts can be successfully removed through mechanical cleaning action and selected cleaning motion modes.
Ultrasonic application of mechanical parts cleaning machine
- Oil and other solid pollutants (oxides and abrasive polishing paste layers) after combustion are deposited on the parts, which requires additional ultrasonic operation
Cleaning process of mechanical parts washing machine
- The solvent system completes the cleaning process in a closed cleaning compartment. The cleaning parts are processed in one or more of the cleaning baskets described above. After the cleaning process is started, the cleaning compartment door will be closed and locked, and the first pre-wash spray will last 1 minute. , Use the heated solvent (the temperature is controlled between 45 ° C and 80 ° C according to different types of solvents and different types of dirt), and spray the components directly through the high-pressure nozzle. The solvent content of the solvent after the first spray is 90%. These solvents are then sent to the distillation unit in the system, and these solvents will all be regenerated into sustainable liquid clean solvents.
- In some cases, it is difficult to remove the pollutants attached to the cleaning parts with complex structures, and then another cleaning spray may be necessary, and the time may be different. Support for ultrasonic action is also available if required, but the optimal frequency and intensity of the ultrasonic waves required for cleaning applications must be calibrated. In the final stage of the cleaning process, preparations are needed for the subsequent drying. In most cases, the vaporized solvent mist is directly applied to the components in the cleaning cabin. These solvent vapors will condense on the parts to remove any residual contaminants. At the same time, the solvent vapors heat up the parts and prepare them for the next stage of drying.
Machine parts washing machine process
- The drying time will vary according to the drying method selected by the system: because the hot air circulation drying system and the vacuum drying system are essentially different. In fact, the solvent recovery inside the system, the residual solvent recovery on the components, and the entire drying process are performed in a completely enclosed environment.
- In some cases, especially in large systems using chlorinated or brominated solvents, the adsorption process must be performed in the final stage of the drying process, which will allow the air in the system to circulate through the activated carbon recovery unit to ensure compliance with volatility Emission standards for the management of organic compounds.
- To operate a multifunctional cleaning system for mechanical parts, you need to know the computer processor that controls all functions. He can choose a series of different cleaning programs, and an instant monitoring system for automatic detection functions and function operation. He provides the cleaning basket movement in the cleaning cabin. The choice of mode can be rotation or swing. These functions are the introduction of the principle of mechanical action to obtain better cleaning ability and faster drying.
Emission Standards for Machine Parts Washers
- The fully enclosed solvent system for the surface cleaning treatment of metal mechanical parts is superior to its extremely low solvent consumption level. The amount of solvent consumption depends on the solvent residues in the distillation box and whether the residue is regularly cleaned from the distillation box, as we have considered For this purpose, we have specially prepared a work instruction book (in general, the residual value of the solvent in the distillation box is <3%, ie. 0.3 liters of residues for every 10 liters of solvent).
- Important international standards specify and limit the maximum consumption and release of solvents into the atmosphere.
- For tetrachloroethylene (risk warning number R40), this is the most widely used solvent in the European Union. The applicable emission limit for this solvent is 100 g / h. VOC Directive indicates that the concentration in the cleaning tank should be less than 20mg / m? The flow concentration cannot exceed 100g / h. This is valid for all compounds of the R 40 class. Conversely, for compounds of the categories R 45, R 46, R 49, R 60, R 61, the applicable emission limit is 2 mg / m and the flow concentration is 10g / h. (According to VOC management regulations, risk warnings need to be graded to identify public hazards and emission restrictions)
- The system absolutely abides by the emission value limit standard. Through the use of a fully-closed circulation system to prevent emissions from the atmosphere and the working environment throughout the cleaning process; the fully-closed system is attributed to the highly efficient built-in cooling system. The used solvent is completely recovered as a clean solvent. The solvent recovery system is closed-cycle, which also ensures that small and medium-sized systems can easily reach the 100g / h emission limit. Large-capacity metal cleaning equipment means that the capacity of its cleaning tank is more than 1 cubic meter, and it is required to be equipped with a more advanced solvent recovery system. After the condensation process, the secondary activated carbon adsorption device is used to further adsorb residual solvents. In addition, when the cleaning compartment door is opened, the remaining tetrachloroethylene vapor will be extracted by the door fan to the same secondary activated carbon adsorption device. By using the adsorption principle, these small amounts of solvents are also collected and recovered. At regular intervals, activated carbon needs to be regenerated: Solvent regeneration is generally set to be completed by a computer automatic memory program before work. Hot air is circulated through the activated carbon bed ("stripping" stage), so that the solvent is completely recovered after condensation and can be reused. Today's technological advances make it possible to reach important emission reduction targets. However, traditional mechanical parts degreasing and cleaning machinery factories are still producing open cleaning tanks and equipped with refrigeration systems. They are freely and freely discharged to the atmosphere. The emission value per square meter of tank surface is Between 1.8 and 5.6 kg / h.