Valve body cleaning and drying line

I. Subversive cleaning ability

1. Three-dimensional *** penetration cleaning

Technical principle: The core lies in the "ultrasonic cavitation effect". High-frequency electrical signals are converted into mechanical vibration through the transduer, generating tens of thousands of micron-level vacuum bubbles in the cleaning solution. These bubbles instantly collapse (implosion) under pressure changes, generating shock waves of more than 1,000 atmospheres and local high temperatures (about 5000K), and their energy directly affects every surface of the valve body.

Solve the pain points: The internal S-shaped channel, small pressure guide holes, multi-circle thread gaps, valve seat sealing surface and other areas of the valve body cannot be effectively touched by traditional spraying, soaking, brushing and other methods. Ultrasonic energy can penetrate into like an "invisible hand", peel off the oil and particles *** adsorbed in it, and achieve *** cleaning in the physical sense.

Comparative advantages: far superior to high-pressure water flow (with dead corners, easy to damage the sealing surface), steam cleaning (uneven effect, high energy consumption), solvent manual scrubbing (low efficiency, poor effect, harmful to health).

2. Mild zero-damage cleaning

Technical guarantee: The cleaning force comes from the explosion of microbubbles, and the range of action is at the micron level, not macroscopic mechanical friction. There will be no scratches, wear or bumps on the precision grinding sealing surface, electroplating or spraying surface, and high-finishing processing surface of the valve body.

Value reflection: Directly protect the core performance and appearance quality of the product, avoid the scrap rate and secondary processing cost caused by the cleaning link, especially suitable for precision valve bodies with *** value (such as instrument valves, aerospace valves).

3. The consistency of cleaning ***

Automation ***: Once the process parameters (such as 40kHz ultrasonic, 60°C, 10 minutes) are set on the PLC, the equipment will effectively execute each batch. The cleaning effect does not depend on the experience, physical strength or working status of the operator.

II. Economic benefits of ***: calculate your input-output ratio

4. Revolutionary reduction in labor costs

Scene comparison: In the traditional way, 2-3 people are required to carry out repetitive labor such as carrying, brushing, rinsing, wiping and drying. This equipment only needs one person to unlead and lower the material (even fully automatic through the robot), and the operation is only "button start".

Digital speaking: Assuming a monthly salary of 5,000 yuan/person, 2 manpower is saved, and the annual direct manpower cost is more than 120,000 yuan. The recovery cycle of equipment investment is usually completed within 1-2 years.

5. Exponential improvement of production efficiency

Time compression: The serial cleaning, rinsing and drying processes, which were originally scattered in many places, are compressed into one device and completed in one cycle (typical cycle 15-25 minutes). It eliminates the waiting, handling and queuing time between processes.

6. Fine savings of operating consumables and energy consumption

Consumables management:

Cleaning agent: Built-in multi-stage filtration system (such as bag filter, magnetic rod adsorption), which can continuously filter metal debris and floating grease, extending the life of high-quality detergents by several times.

Water resources: The second-level countercurrent rinsing design is adopted, that is, the clean rinsing water is replenished into the ***-level rinsing tank, overflowing to the ***-level rinsing tank, and finally used to supplement the main cleaning tank, *** reduces the consumption of pure water/deionized water.

Energy optimization:

Heating: The tank body adopts high-efficiency insulation material, and the heating tube is zoned and controlled. Only the working area is heated, and the heat loss is extremely small.

Drying: The HEPA high-efficiency hot air system is designed with high air volume and low power. The wind speed and temperature can be adjusted, and the heat energy utilization efficiency is extremely high. Compared with the traditional oven, the energy saving is more than 30%.

III. Intelligent automation and *** reliability

7. Humanized intelligent control

System core: industrial-grade PLC (programmable logic controller) + high-resolution color touch screen (HMI).

Functional details:

Formula function: Hundreds of cleaning programs can be stored (such as "ball valve cast iron-heavy oil", "stainless steel needle valve-light oil"), one-click call.

Permission management: Set multi-level passwords for operators, engineers, etc. to prevent parameters from being changed by mistake.

Fault self-diagnosis: The system monitors the liquid level, temperature, ultrasonic intensity, etc. in real time. If there is an abnormality, it will immediately alarm and prompt the cause, so as to shorten the downtime and maintenance time.

Data interface: RJ45 or RS485 interface can be optionally equipped, connect to MES/ERP system, upload production data (quantity, cycle, alarm information), and realize digital management.

8. Process standardization and quality traceability

Core value: For customers with quality system certification requirements such as IATF 16949 (automobile), AS9100 (aviation), *** 13485 (medical), etc., the equipment can provide a complete record of the cleaning process (time, temperature, etc.) to form an electronic report. This means that the cleaning history of each batch of valve bodies is well-founded, realizing the quality traceability of ***.

9. ***-Level structural design and durability

Material: The main structure, tank body and pipe are all made of SUS 304 or 316 stainless steel, and the welding part is polished and passivated, with a corrosion-resistant life of more than 10 years.

Core components: The ultrasonic generator adopts IGBT module, which is effective *** and stable; the energy transducer adopts imported piezoelectric ceramic sheets, and *** long-term power does not attenuate.

Mechanical structure: The lifting transfer mechanism adopts precision rails/screws and pneumatic/electric actuators, with smooth operation, positioning ***, and durability.

IV. Environmental protection, safety and strategic value

10. Strategic tools to improve the core competitiveness of enterprises

Brand image: ***'s automated production equipment is an intuitive embodiment of the company's technical strength and manufacturing level. In customer factory inspection and industry exhibitions, ***'s persuasiveness is the "knocking brick" to obtain high-end orders.

Strategic flexibility: By replacing the cleaning basket and cleaning program, a device can adapt to a variety of different types and sizes of valve body cleaning, which provides a strong production guarantee for the transformation and diversified development of enterprise products.

11. Reduce comprehensive management costs

It reduces the hidden costs of assembly failure and after-sales rework caused by unclean cleaning.

The production management process has been simplified, the production plan is smoother, and the site utilization rate is higher.