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In which area of application is the central filter system used?
A central filter system from Lehmann-UMT GmbH is used for the filtration of cooling lubricants during aluminum processing. The aluminum is currently machined using 39 high-performance milling machines to produce carrier strips for battery systems that are installed in electric vehicles. The system reliably filters aluminum chips down to 10 µm from the emulsion.
What special features in the design of the central system make it so powerful?
"With 500 liters per minute per machining center, we flush the chips out of the machine," says Jonathan Gehmlich, Technical Manager at Lehmann-UMT. The contaminated fluid passes from the machining center to a scraper chain conveyor with an integrated slotted screen, which removes all chips larger than 5/10 mm from the process and thus relieves downstream filters. Mechanical pre-separation removes up to 85% of the chips and only the emulsion with the fine dirt particles is pumped back into the filter system.
The contaminated cooling lubricant then reaches the compact filter, which reliably removes the fine chips from the process and filters down to 10 µm. The clean tank with a volume of 8,000 liters is located under the compact filter. Foreign oils floating on the surface are removed from the process by a belt skimmer so that only the cleaned medium remains in the tank.
Frequency-controlled central pumps feed the clean coolant back to the processing machines. All systems are demand-controlled. This means that only as much fluid is supplied as is actually required in the machining process. Each machine is also equipped with an IKZ pump, which is also efficiently controlled via the central filter system, ensuring reliable internal cooling and a long service life for the machining tools.
The filter system and conveyor technology are fully interlinked and monitored by sensors. The entire system control, pumps and drives are recorded in a central control cabinet. The control system also has an interface to each connected machining center in order to communicate various message statuses and maintenance intervals and to provide coolant as required. The overall system is very maintenance-friendly, easily accessible and low-wear. The control system and therefore the entire system run fully automatically, minimizing manual intervention and personnel costs.
The central system is equipped with an additional remote maintenance module so that support can be provided quickly in the event of adjustments or servicing. The filter system is characterized by a high degree of automation, runs completely autonomously and can be connected to the higher-level building management system. All Lehmann systems are Industry 4.0-capable and can be easily integrated into the existing machine concept thanks to the standard plug-and-play system.
What was the customer's brief?
The aim at the beginning of the project was to implement filtration for a small machining nest of 3 machines. "In the course of the project, we also implemented filtration for an entire production hall with an integrated central chip disposal system," reports Titus Lehmann.
The first step was to define the technical parameters based on a series of tests. The experienced design engineers at Lehmann-UMT then tailored the system precisely to the customer's process and developed the optimum solution for a central plant disposal system by linking individual conveyor systems.
"The project was realized in the last 2.5 years. Over the various expansion stages, a total of 39 machining centers are now connected to the central filter system, each of which requires approx. 500 l of filtered cooling lubricant per minute. This means that the central system filters approx. 20,000 liters of emulsion per minute in this one production hall, which is quite gigantic," explains J. Gehmlich. Plans are currently underway to equip further machining centers in this production line with filter and conveyor technology.
We attach great importance to service and set new standards.
The "all-round carefree package" is one of the many reasons why Lehmann-UMT customers choose to work with us. This service ensures maximum safety and means 360° service from the Saxon Vogtland region. From initiation, through design, coordination with other trades and the end customer, to delivery, installation and commissioning by qualified service personnel, the plant manufacturer provides support with experience and expertise. Lehmann-UMT not only stands for long-term partnerships, but also for quality "Made in Germany". The entire production process of the systems takes place in state-of-the-art in-house production, from cutting on our own fiber laser systems to welding processes, which are carried out by robot welding systems, to powder coating, assembly and the comprehensive worldwide after-sales service, the customer receives everything from a single source.
"A long-term partnership with our customers, even beyond the sales process, is very important to us. For example, we ensure the availability of spare parts for several years and train our customers' employees so that they can also carry out service and maintenance work professionally themselves," explains Titus Lehmann.
What makes the system so extremely sustainable and environmentally friendly?
In general, Lehmann's systems are designed in such a way that they primarily use the energy naturally occurring in the environment, such as sedimentation through gravitational force, hydrostatic water pressure, magnetism and adhesion forces. Titus Lehmann proudly reports: "This makes our products particularly energy-efficient. Not only do they contribute to the sustainability of the customer's production, but they themselves are already manufactured in an environmentally friendly way by covering our energy requirements during production with solar energy generated in-house and the use of waste heat from various other processes." Just last year (2022), the Vogtland-based company invested in a solar system, which was installed on the roofs of the company buildings and now covers the energy requirements of the entire company and feeds surplus energy into the local grid.
