Automatic Lift and Flip Impregnation Plant Infiltration Equipment

I. Impregnation / Infiltration Process
 
· Pre-washed: Spray and clean the product with 60-65 ºC hot water and warm-up, the material basket will continue flipping driven by reversing mechanism, and pour out the water from blind holes, reduce the burden for the following drying process, shortening the subsequent drying time, improve the drying effect.
 
Vacuum drying: Vacuum drying design fast dry the water on the surface under low consumption , improve the drying effect. So that it can fully meet quickly and thoroughly drying process requirements (no more than 10min).
Vacuum impregnation: Equipment is designed with dry vacuum, wet vacuum, pressure, in which the negative pressure -0.098 ~ -0.100Mpa, and pressure 0.4~0.45Mpa, with integrated tank structure for infiltration and glue storage.

Six directions liquid removal: Liquid removal and recovery is designed into 2 steps, the first step is centrifugal liquid removal from the 4 surfaces, then the work basket auto-flip 90 °, the second step is centrifugal liquid removal from the upper and lower 2 surfaces, so that it fully guaranteed blind holes on six machined surface of the work-piece were treated with liquid removal process. It has 2 benefits: 1, Glue consumption dropped; 2, It is conducive to the subsequent cleaning, to ensure that no adhesive residue on the blind holes after curing .

· Cleaning: It washes the work-piece by two-stage flipping and counter-current, insure the blind hole 100% unblocked by glue.

· Curing: The curing tank has a rotary system to reduce a lot of steam into the workshop when the lid opens;

II. Impregnation / Infiltration Equipment
 
Hot water rinsing tank
 
           
            Feeding   --   forward cleaning  --  reverse cleaning   --   discharge
 
1.1 Process Features
 
This step is mainly rinsing the residual cleaning agent on the product, water temperature is adjusted to 60 ~ 70 ºC, not only rinsing the work-piece better, but also preheated it, and provide the necessary conditions for the subsequent vacuum drying. Hot water automatically returns to the rinse tank after the rinsing (the water storage tank has automatic heating and insulation function), the material basket will continue flipping driven by reversing mechanism, and pour out the water from blind holes, reduce the burden for the following drying process, shortening the subsequent drying time, improve the drying effect.
 
 
1.2 Hot water flip rinsing tank instructions
 
a. Tank with 1.5 ~ 3mm thick SUS304 stainless steel.

b. Tanks with insulated water storage tanks, insulation thickness no less than 40mm, with good insulation effect.
c. The tank is equipped with electric heating, adjustable room temperature ~ 100 ºC.

d. The tank is equipped with steam pumping system to avoid large amounts of water vapor into the shop and pollute the environment when the lid is opened.

e. Upper and lower tanks are both equipped with level control system, to prevent dry heating accidents and pollution of overflow.

f. It is equipped with centrifugal pipeline pump to achieve clean water circulation, meet the production capacity and process requirements.

g. Water circulation system is equipped with filtration devices to filter larger particles of debris.

h. Flipping mechanism with automatic locking device, is safe, reliable and easy to operate.

i. Pneumatic switch lids, is fast and stable, with low noise.
 
2.Vacuum Drying Tank
 
        
      Feeding         Vacuum Drying        Discharge
 
2.1 Process Features
 
The principle of vacuum drying is boiling point of water reduces with pressure reducing. Put the product with heat into the drying tank, reduce pressure through a vacuum pump in the tank, so that water of product surface, blind holes, deficiencies easily reaches boiling point, vaporizes into steam and sucked out by vacuum pump, then the product is dry. Vacuum drying is not only effective, but also low energy consumption compared to conventional heating drying method, it saves energy. A lot of experiments proved: The water can vaporize at room temperature or even lower temperature under enough pressure condition, but it requires heat during evaporation, water vapor in the defect porous is easy to appear a "freezing" phenomenon in an instant, due to the temperature is too low,   that is why to raise the rinsing product's temperature above 60 ºC. At the same time, expect the water should reach boiling point, the other requirement "pressure decreasing" is no longer so strict, since the product temperature is increased. This will not only speed up the production, but also improve the product drying effect, and reduces the risk of incomplete-drying within a fixed time at room temperature.
 
2.2 Vacuum Drying Tank
 
a. Tank is made of 6 ~ 8mm thick stainless steel plate.
b. First-class brand of vacuum pumps, with reliability, easy maintenance and good vacuum effect.
c. Vacuum system is equipped with a dedicated isolation tank to extend pump life span.
d. It is equipped pneumatic ball valve at each work cycle to ensure idiomatically discharge the condensate water from the dried tank.
e. Pneumatic switch lids, is fast and stable, with low noise.
 
 
2.3Vacuum Impregnation Tank
 
Tank inner diameter: φ1200
Process requirements: 1, Dry vacuumed to 1KPa ~ 1.6KPa, keeping pressure 3~5 minutes.
2, Humidly vacuumed to 1KPa ~ 1.6KPa, keeping pressure 3~5 minutes.
3, Keeping pressure 3~5 minutes
 
Impregnation tank is made of high quality SUS304 stainless steel plate, 6mm thickness and 1.5 mm. The flange is made of machined whole forgings and safe, reliable, beautiful. Fast pneumatic switch lids. The degree of vacuum is no less than 0.098Mpa, enables the vacuum,pressuring and pressure holding keeping ≥24 hours. Liquid inlet and outlet piping, pumping and draining vacuum pipe line fitted with high-quality SUS304 stainless steel pneumatic valve, fast and reliable. The lid is quipped with observation sight glass and lights; it is also equipped with digital vacuum pressure sensor and pressure gauge. 
 
To prevent impregnation liquid flowing into the vacuum pump when pumping vacuum, it is equipped with an isolation tank, the gas discharge nozzle are installed muffler. This system uses the principle of vacuum pressure infiltration, to fill the pores of the work-piece with sealant. The system includes impregnation tank automatic lifting systems, vacuum pumps and chillers.
 
The following are its unique features:
•The top cover is equipped with observation windows to monitor the situation inside impregnation cylinder.
• Two absolute vacuum gauges with different ranges mounted in striking position adjacent the impregnation cylinder, so that the operator can monitor vacuum conditions inside the impregnation cylinder .
• Programs include dry vacuum impregnation, wet vacuum and application absorption state.
•  The chiller of impregnation cylinder keeps the sealant at temperatures below 0 ~ 28 ºC, with adjustable temperature settings.
• Device equipped with an automatic lifting system, when the work-piece frame reaches the preset time, it is automatically decreased for infiltration; when infiltration time finishes,the work-piece box automatically rise to the level above impregnating tank to facilitate the lift operators (currently only Huiyi company can design automatic lifting system).
• It has degassing function to best cures the sealant.
• The insulation thickness is 40mm, and makes the cylinder cooling system for maximum effectiveness.
 
 
   
 Feeding  Dry Vacuum Pumping  Wet Vacuum Pumping   Impregnation     Discharge
 
2.4 Flip rotary glue rejection and recovery tank
 
   Process requirements: 
   1, Forward and reverse rotary time 5 ~ 7min each
2, Forward and reverse rotary speed 0~100r/min adjustable
 
The glue rejection and recovery tank is made of SUS304 stainless steel no less than 3mm thickness, with quick pneumatic switch to open and close lids. After the impregnation process is completed, most of the sealant adhesion can not be discharged but adhere in the complex shape of the work-piece. So put the work-piece into the recovery tank after impregnation , make six surfaces of the work-piece subjected to centrifugal force with the centrifuge rotor system(while flip 90 °). 
 
It solves the problems scrapped parts caused by work-piece hole plugging gum. Put the work-piece basket in the rotating jig to rotate inside the tank, the inverter controls forward , reverse rotary and their speed within a speed range of 0 ~ 100r/min adjustable. Forward and reverse rotary time is adjustable and controllable, so that the excess sealant adhesion of the surface can be discharged, sealant in the recovery tank will be automatically transferred back to the impregnation tank for recycling use.
 
 
      
Feeding -- High Speed Centrifuge Liquid Rejection -- Flip 90ºC Centrifuge -- Discharge
 
2.5  Flipping counter-current spray and rinsing tank 
 
   Process requirements: Forward and reverse rotary time 5 ~ 8min each
Cold water tank is made of SUS304 stainless steel no less than 3mm thickness, equipped with two floors water storage tanks, equipped with convenient removable filter mesh at the nozzle, with quick pneumatic switch to open and close lids. After the recovery process is completed, place the work-piece into a cold water tank to clean sealant adhesion from its surface, with rotary systems and spraying tap design, spray on the rotary work-piece with a lot of water, to maximally ensure the cleanliness of the work-piece. It is different from traditional way of directly soaking the work-piece in the water to clean, because two-stage flip spray cleaning can spray cleans the six surfaces of the work-piece effect. The work-piece is spray cleaned by circulating water while rotating in the cleaning tank, completely solve the plugging gum problems in work-piece threaded holes and blind holes. It has particularly prominent cleaning effect on work-pieces in complex shapes or varsities. It maximally avoids possible contaminants adhering to the surface of the work-piece, particularly in the threaded holes, the contaminants may pollute or clogging the work-piece after curing.
 
      
             Feeding       Flip Cleaning    Spray Cleaning     Discharge
 
 
2.6 Flip hot water curing tank
 
Process requirements: 1, Curing time: 15min
2, Curing temperature: 90 ~ 93 ºC
Hot water curing tank is made of SUS304 stainless steel no less than 3mm thickness, equipped with two floors insulated water storage tanks,the insulation layer is made of SUS304 stainless steel no less than 1.5 mm thickness, equipped with convenient removable filter mesh at the nozzle, with quick pneumatic switch to open and close lids. Hot water temperature is adjustable with 0~99ºC. After the cleaning process is completed, place the work-piece into a hot water curing tank to cure the sealant, then fast and effectively dry its surface, threaded holes and blind holes with rotary system. 
                   

          Feeding --  Hot Water Curing  --   Discharge
 
2.7 Material baskets / Cages (8 pcs)
 
· Material baskets are made of SUS304 650mm×650mm×700mm
• To avoid collision between the work-piece and material basket while the material basket is moving, drying, pouring the liquid , between the work-piece and the work-piece, they are apart with PP screen.
· Since the total weight of the work-piece and the basket up to 200 ~ 400Kg, to reduce labor intensity in the production line, we design movable carriage for the production line and discharge step.
 
                        
2.8. Isolation tank
 
It is equipped with drying filter, pressure relief valve, and large diameter outlet. The relief valve closes automatically when the vacuum pump starts, the relief valve automatically opens when the vacuum pump stops. It promptly discharges water and impurities, avoiding them flow into the vacuum pump, effectively prevent impregnation liquid into the vacuum pump,  ensure the vacuum pump to reach its optimum working condition, extend its life span. 
2.9, Vacuum pump
 
Specific parameters:
         
 
2.10, Working platform
 
(1)The platform is designed for keeping employees safe, it has a working channel and safety barriers to meet the safety requirements.
(2) It is made of carbon steel checkered platform, the platform bracket is made of No.6-10 Channel Steel.
(3) Platform color is coated according to customer requirements.
 
Specific parameters:
Platform deck material safety barriers set 1
1 set of escalators
Q235 checkered jacket platform 1
Hoardings set 1
   
2.11, Lifting device
 
(1) Electric lifting hoist is Zhejiang Kaidao brand. Track bearing load ≥1T.
(2) The top crane is made of 140MM round tube, with oblique support ribs to ensure running stability.
(3) It is compact, small and light.
(4) It runs in linear single-track, it has reasonable structure, smooth operation and low noise.
(5) The support is stable and safe.
(6) It has motor drive and smooth operation.
 
Specific parameters:
  
2.12 Electrical Control System
 
• The system has programmable PLC controller to control the entire infiltration process,  the process parameters can be set on the display screen by entering the relevant values. Display screens show the operating status of each unit, the related parameters and fault alarm in real time.
· The operator control panel is set on the aisle, to facilitate operator control each tank. The operation of each unit is divided into automatic mode and manual mode. Digital meter can display temperature heating and cooling, and set various parameters.



Suzhou Huiyi Impregnation Machinery Co.,Ltd.

Contact:
 
Overseas Market

Ms. Amy Zhou
International Sales Manager

Please e-mail me with your requirements at the following e-mail address:
 


Mobile 0086-153-657-78907

----------------------------
Domestic Market

Mr. Wang Wei
General Manager

 

Phone: 0512-67484837

Web:impregnationtech.en.made-in-china.com

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Automatic Lift and Flip Infiltration Plant Impregnation Equipment

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