Rockwell Automation Conserves Machining Fluids By Implementing a New Filter Technology.

Background

A new filter technology is being employed at one of Rockwell Automation's high tech electric motor facilities. The new technology is MYCELX, a patented hydrocarbon removal system that has been employed on water cleanup applications ranging from PCB remediation in power company's sumps to fuel sheen removal from overturned tug boats.

The MYCELX filters being used at the Rockwell Automation plant are the company's new MachineKleen units which are being used to remove tramp oils from Rockwell's machining fluids. By removing the tramp oil from the fluids the coolant life is greatly extended. Additionally they provide the facility with the added benefit of increased machining quality and reduced downtime.

The Problem

Tramp oil gets into the machining fluid from various sources. The machines have auto-lubers that inject oil to keep the shafts clean and operating smoothly, the metals that are being machined have oils on them to keep them from corroding and the tooling is lubricated for quality and reduced wear. The machine's own hydraulic system leaks tend to be the biggest contributor to machining fluid contamination.

The buildup of tramp oil degrades the heat transfer and lubrication properties of the machining fluids. The oils can cause excessive tool and machine wear as well as bacterial growth in fluid baths.

The Solution

MachineKleen, a patented filter system from MYCELX Technologies Corporation, has been designed to remove tramp oils from machining fluids that are used as tooling coolants in drilling, milling, tapping and grinding operations. The MYCELX filter is able to accomplish this task because of its unique ability to catch large quantities of tramp oils and grease without building a differential pressure.

Historically, filters with sufficient ability to remove enough oil to be effective in this type of application would build high differential pressures during saturation. The MYCELX filters are unique because they able to remove well beyond their weight in oil without building any significant differential pressure. A totally saturated MYCELX filter presents only a 1/2 psi pressure differential to the system, ensuring a constant flow of machining fluid to the tool head.

MYCELX is able to remove the tramp oils from the coolants without degrading the stabilizers, performance packages or biocidal properties. MYCELX filters leave the highly stable emulsion that makes up the machining fluid intact while they remove the tramp oils and emulsified lube oils that pollute and degrade the fluid.

The MachineKleen filter system is simply installed in the sump recirculation hose or spray head injection line to remove the tramp oils before they build up and contaminate the fluid. The 10" filter unit comes with mounting brackets and hose adapters for 1/2", 3/4", and 1" lines. Larger units are available for use on central sump fluid systems.

The Results

Stuart Gardner, Rockwell Automation's Manufacturing Engineering Manager for the Flowery Branch, GA plant has been very impressed with the performance of the MYCELX filters on his electric motor manufacturing line.

Mr. Gardner said, " The Maxim just outside the door has a (MYCELX) filter as well. We replaced it and the particulate filter this week and voila! the pallet wash system is working for the first time in two years. A big win for the operator!"

MYCELX MachineKleen filters are currently installed on all of the horizontal milling, drilling and tapping machines in one of Rockwell's machining centers with a few other MYCELX units placed on various machines throughout the plant where tramp oil buildup is even more exaggerated. Rockwell is also employing MYCELX's CompressorKleen filters on their air compressor condensate lines to keep the plant in compliance with oil discharge regulations.

The Benefits

At this plant alone, the use of the MYCELX filters will save Rockwell over $76,000.00 dollars in coolant and downtime. It has yet to be determined what the savings will be from the reduced machine and tooling wear and the increase in part quality.

Advantages have already been seen from the reduced smoke generation from the lathe operation which is another win for the operator, especially for safety and comfort.

The tramp oil buildup in the coolant used to cause problems in the paint operation as well with poor adhesion and rework. The MYCELX filters have helped out a great deal.

A program of this sort helps the plant engineer in a number of ways, it has:

• Environmental Merit -
  Reduces spent coolant and the costs of disposal
• Cost Savings of Machining Fluid -
  Replacement coolant costs from $8 to $20/gallon
  
• Decreased Maintenance Costs -
  Down time and coolant changeout time costs money. Any reduction in labor or downtime pays off greatly

Environmentally sound and safe to use, MYCELX MachineKleen offers cost savings by giving machining fluids a longer life, reducing lost work time and slashing disposal and maintenance costs. As an added benefit, tooling life is increased along with machining quality and machine wear is reduced.