Centralized Filtration System: Aluminium Machining

Aluminium is vastly used in automobile components. Various operations like drilling tapping on such components generate large quantum of chips. Individual filtration system are prone to breakdowns and do not give required filtration levels resulting in low coolant life.

In a CFS, Dirty fluid along with chips is collected in the dirty tank. This tank has a continuously moving scarper conveyor which removes the chips that settle down. A rotating mesh drum is placed inside this tank. The fluid passes through the mesh drum while the chips are separated on the outside. The filtered fluid drops into a clean tank. Clean fluid pump supply pressurized fluid to the machines. Sizing of the tanks, mesh drum and pumps is done based on your total flow requirement. In addition fine filter housing can be provided for through spindle coolant.


Centralized Filtration System for Aluminium Machining

Features & Benefits

  • Large dirty tank gives sufficient time for the chips to settle. It also improves heat dissipation.
  • Single point chip collection.
  • Independently rotating mesh drum with inward and outward flushing nozzle.
  • Multiple drums for larger systems. Drums can be isolated individually.
  • Our unique seal design reduces the seal size.
  • Multi paneled drum for ease of mesh maintenance.
  • Built in PLC Controlled electrical and mechanical safety with Auto conveyor Jamming logic.
  • Skimmers, Week end agitation, VFD can be added with further enhance the system.
  • Customized design to suit your specific requirement.

Components

Fluid with chips drops in cavity outside a mesh drum. It moves in the drum trough fine mesh, by gravity, leaving the chips on the mesh. Read more
Scraper Conveyer is a simplest device to handle course dirt in bulk. It can be designed in several forms: inserted in a machine tunnel or placed at the bottom of dirty fluid holding tank. It also can be used in combination with a verity of filtration / separation devices.Read more

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Bajaj Auto Ltd

A world class manufacturer in India. They manufacture 2 wheelers and 3 wheelers wide range of products.

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A world class manufacturer in India. They manufacture 2 wheelers and 3 wheelers wide range of products.

Application : Aluminum machining
Process : Machining, Drilling, Tapping, Boring
No of machine : 80 No’s
Fluid : Water based emulsion

Multiple part of a 2 wheeler are made of aluminum die cast. Components are machines, drilled and bored to achieve finished stage. This generates large quantum of chips. Considering the high production requirements multiple machines are working at the same time.

This generates a large quantum of chips. Chips were separated in individual tanks and fluid pumped back to machine. Chips had to be cleaned manually from each tank. This caused significant machine downtime. Customer wanted to reduce this machine down time and if possible completely eliminate it.

Properties of coolant like pH, concentration etc. had to be maintained at each machine. This caused irregularities and required lot of manpower. Due to the space limitation available for individual tanks, filtration level achieved was compromised resulting improper filtration reducing the coolant life and frequent breakdown of machines.

Customer wanted to explore the possibility of adding additional machine in the same shop floor to match the ever increasing production demand

Veeraja proposed a centralized filtration system with large conveyors and mesh drum filters. A layout was prepared with the process planners from Bajaj Auto ltd. Civil trenches were dug in existing machine shop. Advance in civil engineering has made it possible to dig inside the shop floor without disturbing adjacent machines.

Careful coordination with various agencies and technical team Bajaj Auto Ltd ensured that production is hampered the least. A large pit to accommodate a 15000 LPM central filtration which total tank capacity of more than 1,00,000 liters was constructed outside the shop. U shape gutters were fitted in the trenches and a central filtration was installed in the pit. A regularly tracked project execution ensured on time delivery and smooth transition from individual to Centralized filtration system

Individual tanks were removed and dirty fluid outlets of all machines were connected to the U shaped gutters. These carry the fluid and chips to the CFS. Sufficient gradient ensured all is transferred without any blockage and accumulation. Additional flushing nozzles tapped from high pressure supply line are used at regular intervals.

  • Coolant life increased from 3 months to 3 years.
  • New machines were added due to the space saved by removing individual tanks.
  • Manpower was reduced.
  • Lesser breakdown and downtime of machines increased production capacities.
  • Power consumption was reduced by 50%

Industries / Companies Which May Need Centralized Filtration Systems

Our experts will always be happy to help you select proper product / combination of product for your industry application.