Eclipse Magnetics News (Continued)
Honda Eclipse Filtration Task
As a result of unprecedented European demand for the popular Civic three and five door models and the commencement of production of the company’s new off-road CR-V model, Japanese car giant Honda has recently been busy hiring extra staff at its Swindon plant. With a workforce now numbering approximately 4,900, the vast majority of the new jobs are production related, and have allowed an extra shift be added at the plant.
Now in its 21st year of operation at Swindon, the newly created jobs and associated investment clearly demonstrates Honda's long-term commitment to British manufacturing and will enabling the company to substantially increase production from last year’s figure of 190,000 cars to an impressive 250,000 in 2007.
In addition to providing welcome employment, Honda’s considerable investment within Great Britain has brought many commercial opportunities for a wide range of UK suppliers. Typical of the business to be had is the recent project undertaken by well-known UK Filtration specialists, Eclipse Magnetics.
Honda use a special purpose boring and reaming machine that was designed and manufactured by Honda’s own Engineering Division for the critical task of machining engine valve seats. In-line with the company’s philosophy of continuous improvement, the Honda Engineering staff came to the conclusion that potential existed for micro particles of metal, that were carried away in the machine’s coolant, to adversely effect the critical surface finish of the machined valve seat, which in turn could have impair the efficiency of the engine concerned. Mindful of the legendary quality of Honda’s products Peter Jones, the Honda Engineer responsible for the process, considered the various filtration options that would help to eliminate this possible problem. He found the ideal answer to his problem in Eclipse Magnetic’s Micromag.
Peter enthused, “Eclipse Magnetics convinced us that Micromag’s outstanding filtration capability and short investment payback period exactly matched our needs. Since incorporating Micromag into our process, we have found that, in addition to it efficiently removing potentially harmful metal particles, the unit’s maintenance friendly characteristics ensure that we now experience minimum machine downtime compared to our previously used filtration system.”
Ever at the forefront of innovations within the use of advanced magnetic technology, in addition to Micromag, Eclipse Magnetics have developed a wide range of high intensity, super-efficient filtration products that are designed for use across many industrial sectors. Impressed by the rapid pay-back times and the quality improvements that the new Eclipse Magnetics Filtration products provide, numerous companies, both in the UK and in the company’s many overseas markets, are specifying the fitting of Eclipse Magnetics’ high intensity filter systems to a wide variety of applications, within areas such as Machine Tools and Food Processing Plant.
Boasting an extremely impressive sub-micron filtration capability, the unique design of the new Eclipse products enables the efficient removal of ferrous and paramagnetic particles from fluids such as cutting oils, re-circulating coolants, and quenching oils. Each of the ingenious Eclipse filtration systems incorporates ultra powerful ‘Rare Earth’ magnetic material to ensure extremely high magnetic flux fields. Whilst passing through these extremely strong magnetic fields, the ingenious design of the Eclipse Magnetic’s filter chambers alters the characteristics of the fluid’s flow, maximising both the surface area and time available for the advanced magnets to attract and retain all suspended ferrous particles.
The many benefits currently being enjoyed by users of the Eclipse Magnetics high intensity filter system include:
No running costs, no maintenance cost, an end to the downtime normally associated with the changing of filter media, no fluid loss due to changing sodden cartridges, no back-pressure - even when the magnetic cores are totally saturated with fluid, extended Machine Tool, Cutting Tool and coolant/oil life
For further information, please visit:
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Eclipse Magnetics News (Continued)
Magnetic Filtration extends Pump life at ThyssenKrupp
Here, Martyn Cotterill of Eclipse Magnetics, looks at how a manufacturer of automotive components managed to increase the life expectancy of its de-greasing pumps using innovative magnetic filtration technology.
“ThyssenKrupp is well known as one of the UK’s leading suppliers of safety critical automotive sub-frames, chassis and suspension components, counting BMW, Ford, Honda, Jaguar and Volvo amongst its customers. The company recently recognised inefficiency in their production system which came about because each of its products needed to be de-greased before a long-lasting, durable protective coating was applied. The problem was arising because during the manufacturing process, the company’s raw material – usually steel tube – passed through a series of complex sequences, including heavy duty pressing, which inevitably leads to fine steel particles becoming present on the surface of the product. The resulting build-up of abrasive ‘sludge’ within the de-greasing plant meant that this important process was regularly taken out of commission. This was because the fine particles in the sludge led to severe wear on the pumps, which meant that they had to be replaced frequently, stopping the whole line during the changeover.
Our engineering team were brought in to recommend a solution, which proved to be the fitting of a high intensity Rare Earth liquid filter magnet. This meant that instead of having to replace pumps at least once a week, since the magnetic filter was fitted in-line to the pre-pump stage of the process, it has not been necessary to replace one single pump. The savings in terms of reduced down time and equipment costs meant that the payback has been in weeks, rather than months. As this initial installation has proved so successful, ThyssenKrupp is now in the process of fitting our super efficient high intensity liquid filters to their remaining de-greasing lines.
Rare Earth magnetic systems are so effective that they can remove micron size ferrous and paramagnetic contamination from various types of industrial fluids and oils down to the sub micron level. As well as removing debris which extends the life of the de-greasing pumps, magnetic filtration also has very low running costs compared to cartridge or bag filters. Once installed, the magnetic filtration equipment will run 24/7 without the need for operator intervention because there are no consumables to replace.
The filters fitted on the ThyssenKrupp de-greasing equipment benefit from our ‘Easy Clean’ system which simply involves releasing the band clamp, and then removing the contaminated cartridge from the housing along with the magnetic core from the tube assembly. The contamination can then be disposed of for its scrap value and without losing expensive de-greasing fluid. There are also environmental benefits of magnetic filtration as the process doesn’t leave the problem of having to dispose of a ‘sodden’ used filter cartridge, which reduces waste and benefits the environment. The de-greasing plant also made savings because the constant changing of the filter cartridge prior to fitting the liquid filter magnet, was leading to a large loss of de-greasing fluid in the sodden filters.
Liquid filter magnet systems can be utilised in any line that processes pumpable liquids and can be installed at any angle from vertical to horizontal. Rare Earth material used in the filters produce extremely high magnetic flux fields, ensuring the magnets perform efficiently over their life, which can extend to 50 years.
The units can be supplied in standard sizes or built around a customer’s specific requirements. Systems can be scaled to suit any size of application and are capable of multi machine delivery.”
The many benefits offered by liquid filter magnetics including low running costs, minimal maintenance, an end to the downtime normally associated with the changing of filter media, and no fluid loss due to changing sodden cartridges is providing many manufacturers with the ideal solution for removing contamination from their production system. In addition to helping with manufacturing efficiency magnetic filtration can also help meet environmental targets by avoiding the creation of filter media waste and the subsequent need for safe disposal.
For further information, please visit:
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Eclipse Magnetics News
Power Matrix – high speed alternative to clamps and vices!
Eclipse Magnetics, one of the UK’s leading experts in magnetics technology, is re- launching its Power Matrix high-performance, electro-permanent magnetic chuck at MACH 2008. The market is increasingly recognising the benefits of magnetics technology for work-holding, and magnetic chucks are now widely accepted as a high speed alternative to clamps and vices.
Power Matrix offers major advantages, including exceptional power, with 150 ton / m of magnetic pull, enabling huge holding forces to be generated on even modest-sized workpieces. Stepped or shaped workpieces can be easily and effectively clamped with optional pole extensions.
The innovative matrix format uses the latest square pole technology to maximum benefit. Each pole is surrounded by poles of different polarity. This generates a tight magnetic field around each pole and means clamping force is equally high in every direction. The matrix format allows thinner materials to be clamped than is possible on parallel pole chucks. An added benefit is that swarf retention is reduced.
The high power provided by the square pole configuration means that the chuck is only 68mm in height.
John Dargavel, Director – Sales and Marketing at Eclipse Magnetics, explains: “Power Matrix provides a cost effective way of work-holding, enabling the user to quickly and easily machine a number of faces in one single operation.
Customers will also benefit from low chatter, which means a better finish and improved tool life, as well as the speed, ease and convenience of the ability to load multiple parts in a single set-up.”
Power Matrix drastically reduces clamping time because it provides magnetic on/off clamping at the touch of a button. The chuck is also failsafe, meaning that if electric power is lost while a workpiece is clamped, it remains held in place.
Power Matrix is available in two sizes, with either 50mm or 75mm square poles, both of which are offered with standard or high power magnets. The high power version, which is created by having a longer internal magnet length, is suitable for rougher/scaled, alloy or other work where there may not be a smooth surface contact. The standard Power Matrix is suitable for use with flatter materials.
John Dargavel, continues: “Power Matrix is suitable for most machine shop operations where work is carried out on dies and molds, or tool room environments where there is a large variety of workpiece shapes and sizes. The fact that multiple parts can also be loaded simultaneously onto Power Matrix means that it can also become a key part of the main production process.”
Power Matrix is available with a full range of standard tooling options, including angle plates that transfer the magnetism through 90˚ and moving pole extensions which allow uneven or distorted components to be clamped without further distortion. Power Matrix can also be supplied with specialised configurations including tombstones, bolsters and others to suite specific needs.
Sizes of chuck available on Power Matrix range from 400 x 250 to 1000 x 600mm (L x W), all of which are 68mm in height.
The product is offered with a 12 month manufacturing guarantee and is available for ordering now.
For further information, please visit:
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