CONVEYRAISED MULTI STATION WASHING MACHINE

CONVEYRAISED MULTI STATION WASHING MACHINE

Component details:

Component Details

MACHINE OPTION -1 WITH MULTISTAGE CONVEYRISED CLEANING 

GENERAL DESCRIPTION

The washing machine is conveyerized, with separate operating stations .The operating stations are –

1. Component loading

    

2. Component dipping in hot alkaline solution.

    

3. High pressure spray washing inside and outside of the component.

    

4. Hot air drying by using blower.

    

5. Component unloading

    

The machine consists of –

·         Separate Dipping, spray washing and compressed air blow chamber arranged in line direction with pneumatically operated  doors on loading and unloading side of the machine.

·         Separate Washing liquid storage tanks for Dipping and Spray washing, situated below the chamber and integrated to the chamber.

·         Sieve basket filter with magnet is provided for arresting coarse contaminants before entering the liquid to wash tank.

·         Ceramic electric heaters enclosed in SS304 tubes for heating washing liquid from the wash tank and drying air.

·         Separate pneumatic cylinders are used for to and fro movement  of component from conveyer to operating chamber.

·         High-pressure centrifugal vertical spray pump coupled with suction valve for wash spray and high flow pump for continuous circulation in dipping tank.

·         Inline simplex bag type filter for dipping and cartage type filter for wash spray .

·         SS304 Belt type oil skimmer for oil contamination removal.

·         AC geared motor for movement of component and it’s mounting fixture from various stations of operations at a fixed low speed during washing, dipping and air blow.

·         V - Jet spray nozzles positioned from top, bottom and side of component baskets.

·         SS304 air blow nozzles to remove excess solution droplets from the component surfaces in drying chamber.

·         Liquid level indicator cum controller with low level safety interlock.

·         Relay contactors logic based control panel with necessary safeties and interlocks for smooth functioning of the machine with operator control box on front side.

The component to be cleaned is loaded, at loading side of the conveyer.

When operator presses two “cycle Start� push buttons from the operator control box, movement of conveyer takes place, Reed switches sense the position of component. To and fro pneumatic cylinders slides respective components from conveyer to operating chambers. Return stroke of pneumatic cylinders are sensed and all doors of operating chambers are closed down. Once doors are closed  operations start simultaneously in all three enclosed chambers.

Dipping Station:

Pneumatic cylinder dip the component inside  hot alkaline solution with  piston’s  reciprocating action. Continuous circulation of cleaning solution is achieved by using high flow –low pressure pump. Circulating solution is passed through the simplex bag type filter.

Wash Spray Station

 Wash pump starts and pressurized hot filtered cleaning liquid is sprayed all over the components through spray type nozzles from inside and outside of the component. The sprayed liquid alongwith removed contaminants passes through sieve basket filter to wash tank. 

Hot air drying

Blower with heater arrangement is used for  air  blow  through the spray nozzles to remove excess solution droplets from the component surfaces and dry the component.

After preset time of operation in all three stages, the door gets opened automatically and conveyer starts. Operator unloads the cleaned components and loads fresh batch for cleaning.

OPERATING CYCLE

1

SPECIFICATIONS

1

5.         Pump :Spray pump –Vertical, multi-stage centrifugal pump coupled with motor,

6.         Filtration :250 microns sieve basket filter with magnet                                                                   Belt type oil skimmer 50 microns disposable bag type Simplex filter                                                                  inline with dipping water circulation . 20  micron cartage type simplex filter inline                                                                   with wash spray.

7.         Electric heaters        Ceramic heaters immersed in seamless tubes.

8.         Spray nozzles:V-jet , 60 Deg. Spray angle MOC – SS304      

9.         Air blow nozzles:      Straight jet air blow nozzles MOC – SS304

10.       Total connected load:@ 38KW

MACHINE OPTION 2 WITH INDEXING CLEANING

GENERAL DESCRIPTION

The washing machine is indexing type, with separate operating stations. The operating stations are –

1. Component loading/unloading

2. Component dipping in hot alkaline solution.

    

3. High pressure spray washing inside and outside of the component.

    

4. Hot air drying by using blower.

    

The machine consists of –

·         Separate Dipping, spray washing and compressed air blow chambers partitioned in quadrilateral format. Pneumatically operated door only at operated side for loading and unloading .

·         Pneumatically Lifting solution tank for dipping where as fixed liquid storage tank for  Spray washing, situated below the chamber and integrated to the chamber.

·         Sieve basket filter with magnet is provided for arresting coarse contaminants before entering the liquid to wash tank.

·         Ceramic electric heaters enclosed in SS304 tubes for heating washing liquid from the wash tank and drying air.

·         Indexing is achieved by using high torque geared motor, coupled with four arm arrangement.

·         High-pressure centrifugal vertical spray pump coupled with suction valve for wash spray and high flow pump for continuous circulation in dipping tank.

·         Inline simplex bag type filter for dipping and      cartage type filter for wash spray .

·         SS304 Belt type oil skimmer for oil contamination removal.

·         ,V - Jet spray nozzles positioned from top, bottom and side of component baskets.

·         SS304 air blow nozzles to remove excess solution droplets from the component surfaces in drying chamber.

·         Liquid level indicator cum controller with low level safety interlock.

·         Relay contactors logic based control panel with necessary safeties and interlocks for smooth functioning of the machine with operator control box on front side.

The component to be cleaned is loaded; where as washed component is unloaded from the loading/unloading station in front of the operator.

When operator presses two “cycle Start� push buttons from the operator control box, indexing movement takes place, to transfer component from one operating station to another. Following operations starts simultaneously in three operating stations:

Dipping Station:

Pneumatic cylinder lifts the hot alkaline solution tank to dip the component. Cylinder piston’s reciprocating action helps to create turbulences. Continuous circulation of cleaning solution is achieved by using high flow –low pressure pump. Circulating solution is passed through the simplex bag type filter.

Wash Spray Station

  Wash pump starts and pressurized hot filtered cleaning liquid is sprayed all over the components through spray type nozzles from inside and outside of the component. The sprayed liquid along with removed contaminants passes through sieve basket filter to wash tank. 

Hot air drying

Blower with heater arrangement is used for  air  blow  through the spray nozzles to remove excess solution droplets from the component surfaces and dry the component.

After preset time of operation in all three stages, indexing movement takes place from one station to another. Operator unloads the cleaned components  and loads fresh batch for cleaning.

OPERATING CYCLE

1

SPECIFICATIONS

1.         Machine Overall Dimensions        :   3000 x 3000 x 2200(h)mm

2.         Loading height:@ 1000 mm         

3.         Indexing    : Fixed speed with  high torque geared motor

4.         Tank   :Separate tanks for dipping and spray     operations Tank MOC – SS 304, 2 mm thk.

5.         Pump :           Spray pump –Vertical, multi-stage centrifugal pump coupled with motor,

.

6.         Filtration:250 microns sieve basket filter with magnet                                                                   Belt type oil skimmer 50 microns disposable bag type Simplex filter                                                                    inline with dipping water circulation 20 micron cartage type simplex filter inline                                                  with wash spray.

7.         Electric heaters:Ceramic heaters immersed in seamless tubes.

8.         Spray nozzles:          V-jet , 60 Deg. Spray angle MOC – SS304        

9.         Air blow nozzles:Straight jet air blow nozzles MOC – SS304

10.       Total connected load: @ 39KW

MACHINE OPTION 3 CABINATE TYPE WITH ALTERNATE DIPPING AND WASH SPRAY

GENERAL DESCRIPTION

The washing machine is cabinet type with common operating station, where two components are washed simultaneously .One by one operating cycle involves –

1. Component loading

    

2. Component dipping in hot alkaline solution.

    

3. High pressure spray washing inside and outside of the component.

    

4. Air purging through water spray line

    

5. Hot air drying by using blower.

    

6. Component unloading

    

The machine consists of –

·         Common Dipping, spray washing and compressed air blow chamber with pneumatically operated  canopy.

·         Common Washing liquid storage tank is used for for Dipping and Spray washing, situated below the chamber and integrated to the chamber.

·         Ceramic electric heaters enclosed in SS304 tubes for heating washing liquid from the wash tank and drying air..

·         High-pressure centrifugal vertical spray pump coupled with suction valve for wash spray and high flow pump for continuous circulation in dipping tank.

·         Inline simplex bag type filter for dipping and cartage type filter for wash spray .

·         SS304 Belt type oil skimmer for oil contamination removal.

·         Pneumatic cylinder with guide rods is used to dip the components inside washing solution.

·         V - Jet spray nozzles positioned from top, bottom and side of component baskets.

·         SS304 air blow nozzles to remove excess solution droplets from the component surfaces in drying chamber.

·         Liquid level indicator cum controller with low level safety interlock.

·         Relay contactors logic based control panel with necessary safeties and interlocks for smooth functioning of the machine with operator control box on front side.

Two components to be cleaned  are  loaded on the component mounting fixture.

When operator presses two “cycle Start� push buttons from the operator control box  till the canopy closes and  AUTO cycle starts. Movement the door shut down, limit switch  sense the door position.

Pneumatic cylinder dip the component inside hot alkaline solution with  piston’s  reciprocating action. Continuous circulation of cleaning solution is achieved by using high flow –low pressure pump. Circulating solution is passed through the simplex bag type filter.

  Wash pump starts and pressurized hot filtered cleaning liquid is sprayed all over the components through spray type nozzles from inside and outside of the component.

After wash time is over, wash pump stops; “purging1� starts. During purging compressed air is blown through the spray nozzles to drip off residual the cleaning liquid from the nozzles

Blower with heater arrangement is used for  air  blow  through the spray nozzles to remove excess solution droplets from the component surfaces and dry the component.

After preset time of operation in all three stages, the door gets opened automatically and conveyer starts. Operator unloads the cleaned components alongwith baskets and loads fresh batch for cleaning.

OPERATING CYCLE

1

SPECIFICATIONS

1.         Machine Overall Dimensions        :   2500 x 1800 x 2200(h)mm

2.         Loading height                                 :@ 1000 mm

3.         Pneumatic cylinder for dipping with reciprocating action.

4.         Tank                                       :Common tank for dipping and spray     operations                  Tank MOC – SS 304, 2 mm thk.Tank insulated with 25 mm thk Rockwool

          cladded with 1.2 mm thk MS sheet. 300 litres

5.         Pump :           Spray pump –Vertical, multi-stage centrifugal pump coupled with motor,

6.         Filtration                                            :250 microns sieve basket filter with magnet    Belt type oil skimmer 50 microns disposable bag type Simplex filter inline with dipping water circulation, 20  micron cartage type simplex filter inline with wash spray.

7.         Electric heaters:Ceramic heaters immersed in seamless tubes.4.5 kw, 3 Nos

8.         Spray nozzles:          V-jet , 60 Deg. Spray angle MOC – SS304        

9.         Air blow nozzles       :           Straight jet air blow nozzles MOC – SS304

10.       Total connected load:@ 23KW

CONSTRUCTIONAL DETAILS :

The material of construction for tank, body & body cover will be stainless steel. Body cover is hinged and provided with pneumatic cylinder arrangement for easy opening & closing. The operation of body cover opening / closing is automatic.

The tank is insulated by using glass wool where as all fixed piping is covered by asbestos rope to reduce heating losses. 

Spray piping , external rigid piping from tank-pump- filter and all water spray - air nozzles are of S.S.

Base frame with out side supports are of MS and painted with synthetic enamel paint.

 SPECIFICATIONS AND MAKES OF MAJOR BOUGHT OUT ITEMS

Sr. No.	Item Name	Specifications	Make
1	Spray pump with motor	100 lpm @ 15 bar capacity, centrifugal pump, vertical 5.0 KW	WILO
2	Pump suction valve	40 NB butterfly valve, CI body, SS304 disc & EPDM seat	Normex
3	Tank drain valve	32 NB Ball valves, SS304 ball, Brass plated body, Full bore, End connections   1 ¼� BSP screwed	Star
4	Oil skimmer	Belt type oil skimmer, SS304 disc,	Swan System
5	In line filter	Simplex bag type filters, 50 microns 7� Dia, 16� long PP, Housing SS304	Swan Systems
6	Electric heaters	Ceramic heaters. Rating – 4.5 Kw	Vishwesh Enterprises
7	Pressure gauge for spray pump	4� Dial, End connections 3/8� BSP (M). Range 0-21 bar	waika
8	Pneumatic cylinder for canopy opening / closing	Double acting cylinder, Model DNC-63-500-PPV	Festo/janatics
9	Solenoid valve for cylinder	5 – 3 way, ¼�, Coil voltage 230 VAC	Festo/janatics
10	Solenoid valves for air blow & purge	Diaphragm type, ¾� BSP (f), 2 way ON / OFF valves, NC, 230 VAC	Avcon
11	Washing spray nozzles	V-jet, 60 deg. Spray angle, 2.5lpm capacity at 15 bar, MOC SS304, end connections 1/4� BSP	Spraytech
12	Air filter regulator	G1/2, with manual drain & pressure gauge	Festo

FEATURES OF THE MACHINE :

1.            Separate and simultaneously operating stations for Dipping , wash spray and hot air drying

2.            Glycerin field  Spray pressure indicator

3.            Interlocks for pneumatic cylinders positioning.

4.            Liquid level indicator cum controller.

5.            Tower lamp for machine status indication

6.            Two set point temperature controller.

7.            Desired slope is provided to avoid solution accumulation.

SAFETIES AND INTERLOCKS

• In Auto cycle mode Cycle will not start unless –

   

Liquid level in the tank is above the minimum working level.

Pump & drive motors are not tripped.

• Heaters in the tank will cut off when the liquid level in the tank falls below minimum working level.

   

• Spray and dipping operations will not start unless doors are in closed position in Auto cycle.

   

·        When “Emergency OFF� button is pressed, the machine will stop as it is and will not start unless the Emergency switch is released.

UTILITY REQUIREMENTS :

Electrical supply                   :           415 V, ± 6%, 3 Ph, 4 wire, 50 Hz ± 3%

                                                            Total connected load @ 20 kW.

Compressed Air supply      :           Air connection ¾� BSP

                                                    Air required at 5.0 kg / cm²

                                                Air consumption @ 60 cfm at 5.0 kg / cm²

Water                                      :           450 Ltrs.for initial filling for dirty tank

25 Ltrs / shift for Make up.

Washing chemical              :           Alkaline cleaning liquid

For initial filling (5 -7%).

Drain connection                 :           1 ¼� BSP