//Air technology ensures optimum dimensional accuracy in precision tool manufacturing

Machining
Usually released cooling lubricant emissions are captured directly within encapsulated machines. Thereafter, they are grouped together in different lines (separated by emulsion- and oil-cooled) and fitted with a central filter system. Thus, the coolant circuit is closed. The filter system used in both cases is the Kappa AirdryTM. Through the intelligent design, it allows individual configuration to filter emulsion or oil mists.

Dry machining

In dry grinding, brushing, etc. processes, emissions are related directly to the machines and manual work. Finally, they are deposited in the highly effective Kappa Central dedusting system. Depending on the requirements, different Kappa dedusting systems are employed.

Diffuse emissions and waste heat
Diffuse emissions arising from open, unencapsulated machines and due to upstream and downstream processes are eliminated via the Kappa A.I.R.TM inhall air cleaning system. The removal and recovery of waste heat is integrated into the overall system. There, the emissions and waste heat are completely captured and carried away under the hall ceiling by the Kappa A.I.R.TM. They are then filtered in the Kappa MTA exhaust air cleaning and air treatment station. As a result of this, the waste heat is recovered with a high level of efficiency. Fresh air is drawn in from outdoors, filtered and heated by the recovered thermal energy to the desired level, or cooled to the temperature required. Thus, the temperature can be maintained throughout the year in the customer's required tolerance range. Thus, the tempered fresh air is introduced into the hall at the floor by Kappa DiffusersTM, ensuring the perfect climate. Through the diffusion of fresh air, it is distributed without draught throughout the entire hall, without mixing with the contaminated hall air. The air flows around all obstacles, and the employees are supplied with fresh air. A stable pool of fresh air was achieved in the working area in just a short period of time. This actively displaces the released emissions and the waste heat from the work and lounge areas up toward the hall ceiling, where they are extensively collected and discharged via the adjustable Kappa COC suction plates.

Outcome:

  • Fresh clean air throughout the entire hall
  • Active displacement of the emissions from the working area
  • Removal of emissions from the hall (no concentration of emissions)
  • Removal of waste heat from the hall (no overheating)
  • Lowe heating costs due to recovery of the existing excess heat
  • Lowe cooling costs due to the use of outside air

Demand based plant operation saves energy
Regulation of the air flow is usually based on demand. The Kappa Zeromatic® automation solution automatically regulates the performance of individual systems and the entire system, depending on the utilization rate during production. With increased utilization, the system power is increased, and at low utilization it is reduced. This considerably reduces the total energy consumption.  


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EMUGE-FRANKEN Präzisionswerkzeuge GmbH from Wolfern (Austria):

   

For over 90 years, the company group EMUGE-FRANKEN has been producing cutting edge threading, gauging, clamping and milling technology. Among their wide range of customer industries are not only the automotive, power generation and aerospace industries, but also mechanical and plant engineering. Their products are exported all over the world and ensure optimal, highly efficient manufacturing processes. They decided to build their location in Wolfern.

Initial situation:
At the former site, attachment filters were in use on the machining centres. However, these required a great deal of maintenance. In addition, the air quality was relatively poor. Making matters worse, the hall overheated, because the excess heat could not dissipate. The completely new building in Wolfern should address these shortcomings.

The Kappa solution:

The new building was equipped with the Kappa A.I.R.TM inhall air cleaning system with integrated climatization (cooling and heating). Thus, 100% fresh air is ensured indoors. The cooling lubricant emissions and fine dust in dry machining are directly collected and deposited. The waste heat is completely removed from the hall and recovered for heating. The energy requirement for cooling is small, since additional cooling energy is only required at outdoor temperatures above 18-20 °C, due to the fresh air cooling. The integrated energy efficiency package ensures on-demand system regulation. This reduces operating costs.

What the customer says:

"Due to the permanent exchange of indoor air and the constant temperature of +/-1 °C in the production areas, the quality of our tools has increased enormously. There are no deviations due to temperature fluctuations in the hall. A big thanks to KAPPA for their professional interpretation and implementation of the system". Josef Kröll, Sales Manager at EMUGE-FRANKEN.

>> GRADAUER GmbH, from Steinbach (Austria):

   

The company GRADAUER specializes in the servicing and development, manufacture and supply of high-quality cutting tools and specialist tools. Its customers include leading companies from the automotive industry, moulding and machine manufacturers, and also the plastics and wood industries.

Initial situation:
Attachment filters were used on the processing machines with oil cooling. The processing machines with emulsion cooling were equipped with a central filter system, within which dry processing was integrated. The filtered emissions were dissipated without recovering excess heat. This resulted in high energy costs. In addition, the hall overheated. It was therefore necessary to rehabilitate the existing hall ventilation system.

The Kappa solution:

Even with GRADAUER, the Kappa A.I.R.TM hall air purification system was designed and installed as a turnkey solution. Employees are now supplied with clean fresh air throughout the hall. This is due to the highly effective filtration of emissions by Kappa Central filter systems - separated by oil and emulsion mists as well as dry machining. The waste heat is dissipated and, through this, the hall is efficiently heated. If the external temperature exceeds the required temperature level, the fresh air is additionally cooled. The performance of the entire air conditioning system automatically adapts to the respective requirements.

What the customer says:

"Due to the constant temperature level in the hall, deviations due to temperature variations no longer occur. We are therefore able to produce our precision tools with the highest accuracy. In addition, the set-up times have been reduced, resulting in an improved output. Our employees are supplied with fresh air throughout the hall and have available a comfortable, properly tempered working environment. Employee satisfaction has increased significantly with the investment." Markus Gradauer, Managing Director of GRADAUER.  

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RABENSTEINER Präzisionswerkzeuge GmbH & Co KG, from Sierning (Austria):

   

The company RABENSTEINER develops and manufactures high-quality cutting tools for high-tech companies that make high demands on their tools in the micro range. These include leading companies across the globe from the fields of mechanical engineering, tool and mould manufacturing, automotive, aerospace, research and development, optics and eyewear industry, medical technology and precision engineering. RABENSTEINER exports its machining tools worldwide. Its main markets are Central Europe, Brazil, Turkey, China, the USA, Canada, Saudi Arabia and Russia.

Initial situation:

At the former site, attachment filters were in use on the machining centres. The air quality was poor despite the use of attachment filters. The desired air quality could not be achieved, and the hall overheated because the waste heat was not dissipated.
In Sierning, a completely new building was constructed for the company. The hall should be clean (meaning emission-free) and heated and cooled and in an energy efficient manner.

The Kappa solution:
The planned and executed Kappa A.I.R.TM hall air cleaning system was to provide RABENSTEINER with zero emissions in the production hall, and energy-efficient heating and cooling. Again, the coolant and the dry emissions are deposited in separate Kappa filter systems. The diffuse emissions are captured, together with the waste heat, at the hall ceiling. For energy-efficient heating, the waste heat is recovered. The air purification system is also equipped with a cooling system. Operation is load-dependent, thus minimising operating costs.

What the customer says:

"With the system from Kappa, all of our problems in terms of air and climate have been solved to our complete satisfaction. Now we are able to manufacture and measure in an air-conditioned production environment without temperature fluctuations, which ensures the consistent quality of the cutting tools. The excess heat from the CNC machines is permanently sent back into the system during the heating period for recycling. The diffusers provide manufacturing personnel with conditioned, filtered fresh air around the clock, without draught. We are happy to have available to us the experience and products of Kappa." Hans Rabensteiner, managing shareholder of RABENSTEINER.

 

Steyr-Gleink, October 2016