Vapormatt Jaguar
Innovative aluminium extrusion die cleaning and polishing system unveiled by Vapormatt at METEF 2008
New ‘Vapormatt Jaguar’ machine is a major breakthrough
At this year’s METEF 2008, leading specialist in wet blast surface cleaning and processing, Vapormatt Ltd, has unveiled the Vapormatt Jaguar what the company claims is a “major breakthrough” in the cleaning and edge preparation of aluminium extrusion dies.
The new, fully enclosed, ‘ Vapormatt Jaguar’ embodies an innovative and radical approach to the cleaning of dies: it utilises an in-line processing concept that offers important production benefits, including faster processing, a more effective and consistent cleaning action than conventional systems and easy integration into existing production layouts. Competitively priced, the Jaguar also has a much smaller footprint than existing die cleaning systems – saving space – and incorporates a highly dependable process control system, which is less prone to “software bugs”, thereby reducing possible machine downtime.
Machine trials in a production environment have already shown that using the new machine can completely eliminate the need for final hand polishing following the cleaning operation, saving time and labour.
Of a modular streamlined design, the Jaguar has the appearance of an advanced production machine in keeping with state-of-the-art production facilities, and is constructed in high-grade stainless steel, seamlessly welded to form a water- and dust-tight, robust structure.
The Jaguar will automatically wet blast, wash, rinse and dry up to 80 extrusion dies and segments in 60 minutes – a significantly higher production rate than comparable systems. The dies can range indiameter from 200mm to 900mm, which covers most normal requirements. The machine operates on a progressive basis to maintain smooth, interruption-free throughput.
More information on Vapormatt die cleaning can be found here >
Dies are loaded directly onto a 900mm diameter processing trolley, which can be loaded by overhead hoist or linked to an existing roller conveyor system. The trolley rolls into the main wet blasting enclosure, which features a special (patented) arrangement of 12 wet blast nozzles, operating concurrently: eight nozzles above the dies and four below. The nozzles oscillate across the dies surfaces as the trolley traverses though the enclosure at a constant speed.
The eight-nozzle array positioned above the dies is of a brand new, hydrodynamic design, and is fed continuously via a common manifold, which supplies both the slurry cleaning media and compressed air at a pre-determined rate and mixture. The nozzles are positioned at pre-set angles to ensure complete coverage around the die cavities and edges and highly effective penetration into and through the orifice on the pressure face.
The four fixed lower nozzles are also positioned strategically to achieve effective overall coverage of the lower die faces. Both sets of nozzles are height-adjustable to accommodate different die thicknesses.
After the wet blasting stage, the work trolley progresses to the tunnel wash section, which comprises a pre-wash stage and two powered rinses that ensure that all traces of the blast media and any debris are removed from the dies prior to drying. The second rinse includes the application of a rust inhibitor to preserve the surface condition of the dies if consequent long-term storage is required.
The drying stage then follows. Drying utilises the machine’s common compressed air supply to provide high penetration, high pressure drying, using air jets mounted above and below the dies. This effectively removes all traces of moisture from the die faces and orifices. A common criticism of using wet blasting, rather the alternative of dry blasting for extrusion die cleaning, is that wet blasting may leave moisture traces on the die surfaces; the new integral drying system employed by the Jaguar guarantees the removal of all moisture, eliminating the potential problem.
To ensure optimum cleaning performance, the Jaguar features an enclosed slurry conditioning system utilising a Vapormatt “elutriation” tower. This (patent pending) system automatically removes abrasive particles that have degraded below a pre-set level from the slurry to maintain consistent media integrity. Debris is deposited into a removable collection tank inside the machine. A slurry sedimentation unit is fitted as standard, as is a pumped drainage system; the latter enables the machine to be located at a distance from drain outlets. Internal distribution pipework is in Vapormatt ‘VSPS’ abrasion-resistant polyurethane, eliminating the use of steel pipes and threads. The vortex electric slurry pump is IP55 classified and fitted with a stainless steel filter. If required, there is the option of an integral wash water recycling system, linked to an automatic moving bed filtration unit.
The Jaguar incorporates a proven control concept, selected for high dependability and minimal downtime in tough operating conditions. Some modern, PLC- or computer-based control systems can cause problems, resulting from intermittent software “bugs” and incompatibility with other factory or production computer systems (the use of different manufacturers’ PLCs, for example). With the Jaguar, Vapormatt have opted for its own straightforward relay logic system, ruggedly designed to offer the required programmability without unnecessary sophistication. The control panel and all electrical components are located at the front of the machine.
All services and support systems are enclosed within the machine and are easily accessible via removable, sound-deadening panels for ease of maintenance. The use of strategic acoustic insulation in other areas of the machine also helps to achieve effective noise reduction. Vapormatt believes that the Jaguar is the quietest machine in its class.
Because the machine is fully enclosed, with sealed processing enclosures, it also offers important health and safety benefits, as there are no potentially dangerous protrusions or the need for manual access or intervention into the enclosures.
All machine access doors are safety-interlocked and internal bulkhead lighting is included, rated to IP65. The processing enclosures have ventilation/air extraction via ducting to the factory exterior, with the option of an air extraction/filtration unit fitted to the roof of the machine, with exhausted air fed into the production area.
Overall dimensions of the Jaguar are 4500mm long x 1600mm wide x 2400mmm high – the smallest footprint for a machine of its kind. Weight is approximately 1500kg.
The major advantages of Vapormatt wet blast cleaning
Vapormatt wet blast cleaning of aluminium extrusion dies leaves a clean surface that requires only minimal or – in many instances – no hand polishing at all after the cleaning stage, thereby saving hours of manual work. The process also creates a fine surface finish and allows higher utilisation of a die before re-cleaning becomes necessary.
The operation of the process is much “gentler” and less aggressive on the die surfaces than dry abrasive blasting, due to the inherent lubricating effect of the water-based slurry – this protects delicate edges and minimises the risk of edge burring or excessive rounding.
Wet blasting also continually washes the surface: trace elements of caustic materials left in cracks and small holes resulting from prior cleaning stages are washed away, leading to better adhesion of any subsequent nitride coating.
Added to this, because wet blasting produces a very fine-grained effect, surface inspection is facilitated, allowing micro-cracks and other defects to identified and rectified more easily.
Importantly, no solvents or other potentially hazardous chemicals are used in the process, so it is not subject to stringent EU solvent emission, VOC or dust emission legislation. Vapormatt offers a total machine support package for the Jaguar, including contract maintenance plans, planned spare parts and consumables programmes and ongoing technical support.
More information on Vapormatt die cleaning can be found here >
