Case Study Details

Client Name

Schunk GmbH & Co KG

PDF Download

Initial Situation

In the past, the Toyoda machine tools were operated with an insufficient solution for collecting and extracting aerosols.. Due to the extreme development of mist from the emulsion in the processing room of the machine, cooling lubricants escaped at the workplace and into the sur-rounding area. This resulted in an increased health risk for the machine operators and a significant contamination hazard for the environment.

Challenge

In mechanical processing, metal-cutting manufacturing using water-mis-cible cooling lubricants accounts for the largest share of processes. One example is the milling of components in an automatic metal-cutting machine. Requirements on the quality are continuing to rise while process times are being reduced so that the collection and dust extraction tech-nology has to meet increasingly higher standards. In the milling process, in particular in the area of automatic machine tools, very fine airborne mists and aerosols are produced due to very high machining speeds and extreme delivery pressures of the cooling lubricants, often accompanied by flying chips. This means that the optimal collection of cooling lubricant emissions already constitutes an essential part of the entire solution. The aim is to collect only the airborne cooling lubricants and not the chips or the directly injected cooling lubricant itself. The effective collection of the cooling lubricant mist is characterised by a very high separation efficiency with minimum clean gas values and long service lives. This is the only way to ensure a solution with high process reliability and high availability. The decisive factor here is the technology.

Solution

A leading manufacturer of gripper and clamping technology required a safe and space-saving solution for the extraction of very fine emulsion mists/aerosols from an automatic machine tool. The collector and the extraction element had to be placed directly on the machine roof, and the limited space available at the location and on the machine had to be taken into account. The emissions are extracted via a special extraction element of the dust gate type directly above the processing point on the machine tool roof. This ensures that only what is necessary is collected and extracted. The fine aerosols are extracted and collected via the emulsion mist collec-tor EM-O Compact with an extraction capacity of V = 1,000 m³/h each. This allowes optimal compliance with the limited space available. The separated emulsion is fed directly back into the machine and reused.

Result

No carry-over of larger quantities of cooling lubricant and chips during ma-chining. Sufficient ventilation of the workspace of the machine tool now al-lows faster cycle times as loading can take place without disruption directly after machining by the staff. Overall, not only the air quality at the workplace and in the production hall but also productivity has improved significantly.