KNOLL AerosolMaster® System with ATS Technology

KNOLL Maschinenbau, Bad Saulgau, has replaced its Minimum Quantity Lubrication system ControLube with the AerosolMaster®system, which is based on ATS technology (aerosol dry lubrication). The system can be supplemented by cryogenic cooling technology. This has come about by the KNOLL acquisition of Rother Technologie GmbH & Co. KG, Bad Urach, including all of its patents, retroactive to July 1, 2019.

For five years, KNOLL Maschinenbau, one of the leading suppliers of conveyor and filtration systems for chips and cooling lubricants in metal processing, has been offering an alternative to wet-cooling lubrication. Managing Director Matthias Knoll is certain that “There are production areas where the future clearly belongs to minimum quantity or dry lubrication.”

Matthias Knoll is sticking to his opinion, even though the company is now discontinuing its previous MQL product – the high pressure ControLube system: “Because of its lubricating results, ControLube is a very good system that produces a particularly fine aerosol. Its disadvantage: It requires a lance through the spindle, which many machine tool manufacturers can not implement. With AerosolMaster®, we have now found an alternative lubrication system that achieves a comparably fine aerosol but is much easier to implement in the machine.”

Rother Technologie. Managing Director Reiner Rother explains: “We were looking for a partner or successor to whom it would make sense to hand over our MQL know-how, which has been acquired over nearly 25 years, and who will continue our products in the long term. KNOLL Maschinenbau, with its experience in the MQL business and its worldwide sales and service structures, was a desirable candidate for us. ”

At EMO, Reiner Rother further described the features of the AerosolMaster® : “Even without a lance in the spindle, we can perfectly lubricate the tool cutting edge and prevent heat from machining.” The technology behind it: The fine aerosol (droplet size 0.1 μm to 0.4 μm) is produced in a pressure vessel via a special venturi nozzle and patented control and regulation technology. Like the usual cooling lubricants, the aerosol is guided along a single channel, for example, through the internal cooling channels of the tool to the cutting edge.

In addition to the high aerosol quality, which has been repeatedly verified at Knoll, Matthias Knoll was particularly impressed by the simple installation: “Not only conventional MQL systems can be converted to the AerosolMaster®. Without much difficulty, it is even possible to convert many wet-cooled machines.”

With the acquisition of Rother, KNOLL has yet another trump card up its sleeve: The AerosolMaster® can be combined with the cryolub® cryogenic cooling technology – also patented by Rother – for example, into the AerosolMaster® 4000 cryolub®. By using liquid CO2, the cutting contact zone can then be cooled down to -78 °C. This is particularly advantageous in the case of heavy-duty machining of titanium and other materials that have a low thermal conductivity. Reiner Rother summarizes this in figures: “With the ‘normal’ AerosolMaster®, we can achieve a productivity increase of 30 to 70 percent; with the cryo system, the increase is even greater, between 70 and 200 percent.”

 

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.

 

 

 

KNOLL High Pressure Unit LubiCool

Introducing the new KNOLL high pressure pump + filtration unit “LubiCool” – a flexible high pressure unit for machine tools, particularly fixed and sliding head stock automatic lathes. The system effectively cleans coolant with a 20 µm belt filter and provides the machine with high pressure up to 150 bar.

Areas of Application

•  Demanding machining processes
•  Deep hole drilling machines
•  Processing with difficult materials (e.g. high-alloyed steel, titanium, copper, bronze)
•  OEM equipment as well as retrofit applications

Operating Description

1. The transfer pump pumps the dirty CL from the machine tool into the compact filter.
2. The compact filter separates chips and the soiling from the CL, which flows in the clean media tank.
3. The dirty fleece is collected in the sludge container.
4. The high pressure pump provides the machine tool with cleaned CL through switchable outputs.
5. The integrated touch pad allows the control and visualisation of the most important system parameters

 

 

 

 

 

 

 

 

 

KNOLL: Central Systems

A completely automatic “System Solution” for the transport or treatment of chips or coolant. These are individual systems and components that are linked to form one complete system – a Central System.

A suitable system depends on the project requirements. This may be, for example, classical, rigid chip conveying systems (belt conveyors) or modern, flexible, cross-linked bulk goods transportation systems (pumping or suction technology). halls and machine layout, machining processes, materials, chip volume and length of conveying path, but also the degree of automation, flexibility, environmental stipulations, disposal costs and budgets are a selection of criteria which our planning experts take into consideration in the design of a suitable system.

KNOLL can offer you all required services, from planning to production to start-up, all from a single source. KNOLL customer service ensures safe and economical operation. Additionally if the system is to be expanded or reconfigured, KNOLL is the right partner for you.

Systems with Pump Technology
A conveyor and filter system with pump technology is suitable for fully-automatic chip transport from several processing machines to a central filter system. Cooling lubricant serves as the carrier medium.

Systems with Extraction Technology
A conveyor system with extraction technology is suitable for fully-automatic chip transport from several processing machines to a central collection point. Room air serves as the carrier medium.

Systems with Collecting Conveyors
Collecting conveyor systems are required to bring metal chips and small parts from production to a central collection point.

Systems for Chip Processing
The treatment of chips has many advantages: they are dry and separated by type, so disposal costs are low. Depending on the material, it may even be possible to sell the chips.

Accessories
As a supplier of complete solutions KNOLL offers customers all accessories for KNOLL Central Systems:

  • Pumps – For the mechanical-engineering and automotive industries
  • Swarf Trolleys – For stable emptying
  • Coolant + Lubricant Tempering equipment – For preheating and heating or cooling of cooling lubricants and other media
  • Foreign Oil Separators – For maintaining cooling lubricants
  • Coolant + Lubricant metering and mixing devices – For metering and mixing stable and homogeneous cooling lubricants or solutions
  • Magnetic Separators – For cleaning cooling lubricants to remove ferromagnetic contaminants
  • Chip Centrifuges – For automatically de-oiling short metal chips
  • Chip Compactors – For briquetting (compacting) metal chips as an economical and ecological alternative to chip processing
  • Lifting + Tipping Devices – Equipment for emptying the contents of chip trolleys or material hoppers into containers, chip mills or centrifuges

 

Please contact us for more information on Central Systems from KNOLL.

 

 

KNOLL Scraper Belt Chip Conveyor K

 

For the transport  of short broken metal chips  and small pieces from machine tools. Installation possible as individual conveyor or interlinked system. Suitable for short steel  chips, needle chips (e.g. brass), cast chips  and cast abrasion, dry processing and wet processing.

Function

A scraper belt continuously moves the material to be conveyed on the container bottom to the discharge point. This continuous scraper belt consists of two chain strands connected through conveying bars. The scraper belt drive is carried out with a three­ phase geared motor with overload protection. Optional limit switch or monitoring of belt tracking. Also pre-­cleaning of the coolant / lubricant is possible with wet processing.

Product Information:

Scraper Belt Chip Conveyor K Brochure

KNOLL Range of Chip Conveyors