Background introduction

在五金加工領(lǐng)域，快速的冷卻和潤滑系統(tǒng)對于確保加工精度、延長刀具壽命以及提高生產(chǎn)效率至關(guān)重要。中心出水過濾系統(tǒng)作為機(jī)床設(shè)備的關(guān)鍵組件之一，通過提供高壓、清潔的切削液或磨削液，不僅能夠有效帶走切削熱，還能防止雜質(zhì)對工件表面造成損傷。上海揚(yáng)譽(yù)液壓科技有限公司（以下簡稱“揚(yáng)譽(yù)液壓”）憑借其在液壓、潤滑及過濾系統(tǒng)的專業(yè)優(yōu)勢，成功為一家機(jī)床制造商定制了一套350 kg central water outlet filtration system, Significantly improved the production efficiency of customers.

Customer demand

During the production process, the machine tool manufacturer found that the existing cooling system had the following problems：

• Insufficient pressure: The coolant pressure provided by the original system cannot meet the needs of high-precision machining, resulting in low cutting efficiency and accelerated tool wear.
• Low filtration accuracy: Traditional filtration devices are difficult to remove tiny particles, which affects the surface quality and dimensional accuracy of the workpiece.
• Inconvenient maintenance:The traditional system has a complex structure, and the replacement and daily maintenance of the filter element are time-consuming and laborious, which increases the downtime.

In order to enhance competitiveness, the customer hopes to find a cooling filtration solution that can solve the above problems, and put forward the following specific requirements：

• Design parameters: The system needs to have an outlet pressure of 500 kg to cope with possible future technological upgrades or process adjustments; in actual use, the outlet pressure is set to 350 kg to ensure that the current processing needs are met.
• Filtration: It can effectively remove particles larger than 1 micron in diameter and ensure the purity of the coolant.
• Stability: Long-term continuous operation to ensure system stability and reliability.
• Maintainability: The design should facilitate daily maintenance and filter replacement to reduce downtime.

Solution

針對客戶的需求，揚(yáng)譽(yù)液壓提出了一套基于中心出水原理的定制化過濾系統(tǒng)方案。以下是該方案的主要特點：

• High pressure pump set: Using a high-performance plunger pump, the output pressure can reach 500 kg, and the actual working pressure can be flexibly adjusted to 350 kg according to customer needs to ensure that the needs of different processing scenarios are met.
• Multi-stage filtration: The system is equipped with a coarse filter element and a high-precision filter element. First, the larger particles of impurities are initially removed through the coarse filter element, and then the high-precision filter element is used for deep purification to ensure that the purity of the coolant reaches the level of 1 micron.
• Intelligent control: Integrated PLC control system, which can realize automatic backwash function, reduce manual intervention and improve work efficiency; At the same time, it has pressure monitoring and alarm functions to ensure the safe operation of the system.
• Material selection: The use of corrosion-resistant, high-strength stainless steel material to adapt to the harsh working conditions in the industrial environment and extend the service life.
• Modular installation: The entire system is divided into several independent modules, which are not only convenient for transportation and on-site assembly, but also conducive to later maintenance and upgrade.

Implementation process

1. Demand research: Yangyu Hydraulics dispatched a technical team to go deep into the customer site to understand the production process and existing equipment in detail, and collect information.
2. Plan formulation: Based on the research results and combined with its own technical advantages, the above-mentioned filtration system solutions have been tailored for customers, and detailed technical exchanges and communications have been conducted.
3. Manufacturing: Organize production and testing in strict accordance with ISO standards to ensure reliable product quality. During the period, customer representatives were invited to visit the factory many times for guidance, and the design plan was adjusted and improved in time.
4. Installation and debugging: A professional engineering team is responsible for on-site installation and commissioning to ensure that the system is put into use smoothly. At the same time, we provide customers with operation training and technical support services.
5. After: Establish a perfect after-sales guarantee system and set up a 24-hour hotline to respond to customer needs at any time; regular return visits and inspections to help customers solve practical problems.

Project results

After several months of hard work, this 350 kg central effluent filtration system has been successfully applied to the customer's production line and has achieved remarkable results.：

• Superior performance: After actual operation verification, the system has fully reached the expected design indicators, which not only greatly improves the cooling effect, but also effectively extends the tool life and improves the machining accuracy and efficiency.
• Economic benefits:Compared with the previous cooling system, the new system significantly reduces the frequency of tool replacement and maintenance costs, reduces downtime, and brings considerable economic benefits to the enterprise.
• Customer satisfaction:Customers expressed their high satisfaction with the products and services provided by Yangyu Hydraulics. The two sides have established a long-term and stable cooperative relationship, which has laid a solid foundation for further expanding the field of cooperation.

Technical highlights

• High pressure stability: The system can operate stably at a working pressure of 350 kg to ensure the continuous supply of coolant or grinding fluid and meet the requirements of high-precision machining.
• High precision filtration: Through multi-stage filtration design, particles larger than 1 micron in diameter are effectively removed, the purity of the coolant is guaranteed, and the surface quality and dimensional accuracy of the workpiece are improved.
• Intelligent control:The PLC control system realizes automated management, with automatic backwash and pressure monitoring functions, which reduces manual intervention and improves the reliability and maintenance convenience of the system.

Conclusion

This case fully demonstrates the professional capabilities and innovative spirit of Shanghai Yangyu Hydraulic Technology Co., Ltd. in the field of customized central water outlet filtration systems. By in-depth understanding of customer needs and providing targeted and cost-effective solutions, Yangyu Hydraulic has not only solved the actual difficulties of customers, but also significantly improved their production efficiency and product quality. In the future, the company will continue to pay attention to market dynamics, continue to develop new technologies and new products, and strive to create more value for customers.