Aluminium is a common material used in the automotive industry. Many automotive parts are made of aluminium die cast. Processes such as machining, drilling and boring are used to produce the components that make up automotive products such as motorcycles and cars. Given that several machines work in tandem and therefore generate a large quantity of chips along with other contaminants, effective filtration systems are of paramount importance. Otherwise, production machinery maintenance has to be carried out frequently, resulting in high machinery downtime and production losses.
Traditional solutions involve numerous individual tanks, pumps and filters dedicated to individual production machines. However, this results in higher complexity, frequent maintenance activities, higher space occupation, and—most importantly—ineffective filtering owing to the smaller size of tanks used to save space. Moreover, because the large quantity of chips have to be cleaned manually from the individual tanks, labor requirements and machine downtime increase to unmanageable levels. Furthermore, it is difficult to monitor the individual filters for quality of filtration as clogged filters are a common problem with individual filtration systems.
A Centralized Filtration System for Aluminium Machining can form the basis to resolve the challenges that arise from such manufacturing operations. However, there is a need for expertise in the specific industry to ensure that centralized filtration systems are tailor-made to individual applications which depend on the workload, the type of fluid being used, and the kind of production machinery in operation. Moreover, Industrial filter suppliers should ensure a non-invasive installation of the Centralized system in the existing production environment.
All these challenges involve close coordination, by the industrial filter company, with different departments to ensure that the ongoing production is not hampered and, if possible, additional space is freed up by carefully planning the filtration system configuration.
An underground storage tank to handle large flows of coolant fluids, up to thousands of LPM, constructed outside the shop can free up a large amount of precious space inside the plant. Gutters, with the appropriate gradient, can be used to convey contaminated fluids to the Centralized filtration system (CFS).
Additional flushing nozzles tapped from a high pressure supply line can be used at regular intervals to ensure that the entire quantity of chips generated from the manufacturing process is conveyed to the filtration system, leaving the gutters clean for continual, free-flow of large volumes of contaminated fluids.
A centralized filtration system allows easy monitoring of the filtering components and simplifies the maintenance of the filtration mechanism such that the focus is on the production machinery, and not on the filtration system. By eliminating several individual tanks and pumps, huge power savings—up to 50%—can be realized using a CFS. Moreover, the space saved by the elimination of tanks and other filtration paraphernalia inside the shop floor means release of precious shop floor space required for production—and not maintenance—machinery.
After switching to a CFS, leading manufacturers have seen a 10–fold or more increase in coolant life, another benefit that pays back quickly on an investment in a CFS. Owing to centralization and simplification of the filtration system, the overall labour required is reduced. Most importantly, drastic reduction in maintenance time almost eliminates short-term maintenance runs, thereby boosting productivity such that the manufacturer stays competitive with better efficiency and higher productivity.
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