Category: Coolant Handling

KNOLL Case Study: Bosch Power Solutions, Homburg

Together with the Energy Management team from Bosch Power Solutions, Homburg, the team from KNOLL Maschinenbau, Bad Saulgau, installed high-pressure pumps with frequency converters in 50 machining centers to improve efficiency and power consumption. The pumps were equipped with frequency converters to supply the machines with cooling lubricant as needed. The energy savings are on average over 50 percent.

  • KNOLL KTS High Pressure Pump with Frequency Converter

 

Environmental protection, CO2 balance and energy efficiency are the top issues of our time, and industry is also concerned with them intensively. At KNOLL Maschinenbau, Bad Saulgau, they are given high priority in many ways: in the office building, in production, but also in the products, solutions and services offered. As a leading provider of pumps, filters and complete coolant systems, the company promotes the use of frequency-controlled high-pressure pumps for supplying coolant to machine tools – not only as initial equipment, but also as retrofits. In order to determine the energy savings that can be achieved during ongoing operation, KNOLL developed the so-called E-PASS around fifteen years ago. This measurement service and the associated conversion are now used by numerous metalworking companies.

Continue reading KNOLL Case Study: Bosch Power Solutions, Homburg

Cool Clean: CO2 Machine Tool Cooling Solution

Dry machining is essentially machining without the use of any cutting fluid or coolant. Dry machining is typically reserved for certain applications, and it may never completely replace the use of cutting fluids, but is becoming increasingly popular due to:

  • Operator Safety – Reducing fumes and splashing coolant
  • “Dry” may work better for certain metals (Ex. composites, plastics)
  • Eliminates messy work environments

Cool Clean has made significant advancements in dry machining with the ChilAire™ CO2 Machine Coolant Systems. The ChilAire™ offers the performance benefits of a liquid coolant and the environmental benefits of dry machining, all with great economics.

 

Dry Machining Features:

  • Benefits operations that must be “dry”
  • External and through tool cooling capability
  • Precision machining of plastics, PEEK, UHMW, etc.
  • Increases in tool life and tighter hole tolerances
  • Additional capability can be achieved with MQL for certain applications

The process is straightforward. CO2 spray is created through an expansion of liquid CO2 into solid CO2 crystals, or CO2 snow, that are delivered to the machining cutting zone. When the CO2 spray hits the cutting edge, the ice-crystals melt and flash back to CO2 gas in a process called sublimation – capable of absorbing significant amounts of heat. The ChilAire™ system keeps the tool and work piece at ambient temperature, hence preventing thermal shock. Further, by controlling the temperature of the cutting zone, customers can use lower cost cutting tools on applications that typically require expensive tools such as Cubic Boron Nitride (CBN), Ceramic, Polycrystalline Diamond (PCD), etc.

Benefits of the ChilAire™ are as follows:

  • Clean Operator Work Environment
  • No Splashing Coolant
  • Cutting Tool Does Not Experience Thermal Shock
  • Improved Economics
  • No Secondary Cleaning

KNOLL: LubiCool®-S High Pressure Coolant System

 

 

KNOLL’s LubiCool®-S high-pressure unit is designed for mobile use with machine tools in machining processes, particularly automatic lathes with a fixed/sliding headstock. The unit is used to clean the cooling lubricant and to supply the machine with high pressure coolant.

The potential application areas include

  • Challenging machining processes
  • Machining operations involving difficult materials (e.g. high-alloy steels, titanium, copper, bronze
  • Situations where space for installation is particularly limited
  • Initial equipment and retrofitting

For more Product Information:  KNOLL LubiCool®-S High Pressure System

 

KNOLL: VL Vacuum Filter Systems

Application Areas

The vacuum filter VL is a high performance filter for cleaning the coolant lubricants of machining processes, in particular grinding processes. Depending on the requirement, several filter elements can be used for individual machines (locally) or machine groups (centrally). Its special efficiency is a result of high energy efficiency, low cooling lubricant loss and low disposal costs.

  • Production of pure concentrate with low residual moisture as standard without filter aids
  • Optimized filter capacity, filter quality and energy efficiency thanks to a flawless control system
  • Continuous filter process without reverse flushing interuption
  • Forced degasification of coolant lubricants in the filter
  • Can be used for different machining processes, materials and coolant lubricants
  • Problem-free removal of light metal chips

Filtering Process

The contaminated liquid flows through the inlet box into the filter. It then runs through the filter belt into the filter chamber. From there, a filter pump conveys the filtered medium into the clean tank. The vacuum pump generates a vacuum in the filter chamber. The high pressure differential at the filtering surface creates a thick filter cake (concentrate) on the filter belt. This filter cake also acts as a filter medium and separates smallest dirt particles. The filter and vacuum pumps are regulated demand-driven and and provide for a tranquilized, constant filtering process.

Filter Belt Regeneration

The permeability of the filtering surface decreases as the filter cake grows. Now the belt drive switches on and conveys the carrier belt together with the filter belt a little further. Thereby, permeable filter belt reaches the filter surface and the volumetric flow through the filter surface continues to rise again. The feed length varies in such a way that the set clock cycle remains constant.

The endless filter belt passes through the following stations:

  1. Filtering section (separation of the dirt particles)
  2. Drying section (extraction of liquid from the concentrate)
  3. Cleaning with air or brush (removal of the concentrate)
  4. Back flushing (removal of the residual particles)

Please contact us for more information on KNOLL Filtration Systems for your process.

 

 

EMO 2019 : Knoll Showcases Global Competence

KNOLL Maschinenbau at EMO 2019
Hall 7, Booth C34.

At EMO 2019, the world’s premier trade show for metal processing, KNOLL Maschinenbau will present itself as a global player, whose products –  Conveyors and Filtration Systems, Pumps, and Transport Systems – are widely used in plants all over the world.  KNOLL supplies not just innovative machine tool components, but also large turnkey central systems for coolant, lubricants and chip management.

  • Knoll Central Systems

KNOLL’s core business – systems for cooling lubricant and chip management – has taken on new dimensions. In addition to outstanding standard components for machine tools, there are also numerous large Central Systems, which KNOLL has delivered to metal processing production operations all over. These systems can supply 30 or more machines with up to 12,000 l/min of extremely clean cooling lubricant. Modular system technology enables them to achieve still greater total output. At EMO visitors can get an impression of this expertise.

In Hall 7, Booth C34, KNOLL will present cooling lubricant in the form of a stand-alone solution for two-stage cooling lubricant filtration.  After the show, this machine will be used by a customer in an HSS grinding shop. It contains a 240/AK5 MicroPur®filter, which is supplemented by a KNOLL KF 400-E compact filter with an endless filter belt. It handles the task of chip pre-separation, making superfine filtration easier.

Innovative Standard Components

The basis of every large system is innovative standard components that are also used in many individual machines. These include the modular superfine MicroPur® filter, which is designed to remove residues from grinding processes, whether carbide metal, HSS or Cast particles. At EMO, KNOLL will present the MicroPur® in the 120-F version, which contains two back flushable filter elements for approx 120 liters of filter capacity. It is particularly cost-effective when working with the integrated KNOLL AK5 automatic concentrator, which reduces the carryover of oil and can ensure a residual moisture content in the settled material of less than or equal to 10%.

For over a year, KNOLL Maschinenbau has offered the LubiCool® mobile high-pressure station for use on short and long automatic lathes. It supplies cooling lubricant at up to 150 bar, which ensures short processing times and longer tool service life for short-breaking chips. Machines are made suitable for even the most challenging of machining processes, such as machining high-alloy steels or titanium. The built-in belt filter with a filter fineness of up to 20 µm guarantees the cooling lubricant purity that is required for high-pressure applications.

At EMO, the “big brother” LubiCool® L will celebrate its premiere. It is designed for larger lathes and small and medium-sized processing centers that require higher flow volumes and flushing processes. Here, high-pressure pump KTS 25-50 can be used with a TG 30 centrifugal pump for flushing. Optionally available for integration is a BS 40 lifting pump, which guarantees independent high-pressure and supply systems.

Both LubiCool® variants use the new SmartConnect operating concept, with which a small industrial PC is connected to the PLC system. Using a 7″ touch display, the user can access the system, visualize states, check parameters, and thus change to manual mode.

Refreshingly Different – the Modular Machine

Based on the structural principles of a processing center and an ideal presentation platform for KNOLL OEM products: the Modular Machine.  KNOLL will display its Plate Conveyor design, as an example, whose distinguishing feature will be plates that are joined hinge-free so that it is suitable both for chip removal for wet and dry processing, as well as conveying small sheet metal parts.

For applications that create very fine, lightweight chips, KNOLL has developed another complementary solution: an attached, self-priming BS 40 dirty water pump which conveys cooling lubricant that contains chips into the chip separator, using the cyclone principle to separate the chips from the cooling lubricant and store them in the ascending area of the conveyor belt. The pre-cleaned coolant flows directly to the filter system.

This is present on the Modular Machine in the form of a KF 150/650 Compact Filter. The universally applicable tower model belt filter saves space since the filter elements sits on the tank.

As a conveyor alternative, the Modular Machine includes an RKR return pumping station with chip reducer, which will demonstrate how cooling lubricant and chips can be transported away from the machine reliably, cleanly, and in space-saving fashion to a central separator/filter.

At EMO 2019, the Modular Machine will, for the first time, contain a fluid cabinet, which includes a pressure boosting system with KTS screw pump, valve technology, and control filter.

MMS instead of Cooling Lubricant

For many chipping applications, Minimum Quantity Lubrication (MMS) is an alternative to using cooling lubricant. For this, KNOLL offers the modular ControLube MMS system, which works with injector technology and microprocessor control. The system developed by KNOLL already delivers a particularly fine aerosol within 0.1 seconds, which provides for improved process conditions, shorter processing times and lower costs. A core property of this MMS system is the oil quantity that can be regulated regardless of the air pressure; it is also available in the simplest ControLube model. Depending on requirements, the system can also be retrofitted process-specifically with additional modules and, for example, with a controllable air pressure of up to 20 bar.