Our new Advanced Powertrain impregnation (APi) system simplifies and compacts the vacuum impregnation process so that you can bring vacuum impregnation equipment in house. The APi takes our patented front loading technology and increases the impregnation chamber for large parts-like engine blocks or powertrain transmission cases. (more…)
The Continuous Flow Impregnation (CFi) System is a lean, front loading vacuum impregnation system that uses a robot for part handling and transfers between modules. This impregnation system has a cycle times of less than 95 seconds. Individual part handling leads to many process improvements, such as shorter cycle times, better rinse results without risk of contamination, damage or discoloration. Furthermore, each part passes through an identical process, and process parameters can be directly associated with a particular part (tracking).
Continuous flow is the most recent technology in vacuum impregnation. Continuous flow vacuum impregnation systems are cellular or lean in design, focused on conserving valuable resources including labor, power and floor space while being more ergonomic than batch systems. The individual modules are loaded from the front, eliminating the need for overhead hoists and cranes. These systems impregnate smaller size batches or single components per impregnation cycle. This allows for reduction of individual module cycle times as well as increased mechanical manipulation assisting in the accomplishment of the four basic tasks of the impregnation process.
Modular Manufacturing
In general, lean, front loading continuous flow vacuum impregnation equipment uses smaller modules with little or no supporting infrastructure. Front loading systems can occupy as little as 86 ft2 of floor space and utilize conventional basket dimensions (e.g.: 600 x 450 x 350 mm), which can be adapted to meet specific part dimensions, if required.
Advantages of continuous flow vacuum impregnation systems:
Smaller, self-contained modules requiring less floor space and infrastructure
Increased throughput through faster cycle times with lower end points in vacuum and positive pressure
Smaller payload or single part handling with improved mechanical manipulation of parts promoting enhanced sealant recovery and washing
More repeatable processing reducing the need for inspection
Lower in-process sealant requirements resulting in better control of raw materials
Disadvantages of continuous flow vacuum impregnation systems:
Inability to process larger, heavier parts in excess of 60 Kg
May require custom fixtures or tooling to secure parts during processing
Production Repeatability and Integration
The CFi technology is fully self-contained for quality with the robot and PLC working together to ensure that parts do not leave the cell if they have not met all of the pre-determined process parameters. Likewise, the use of robotics shortens cycle times, improving overall TAKT time and production volumes. At the same time robotic handling provides for repeatable processing while controlling handling damage.
The Continuous Flow Vacuum Impregnation technology offers manufacturers and OEMs the opportunity to completely integrate the impregnation process into their overall production line eliminating labor, reducing WIP and controlling costs. Existing cells deliver over 240,000 cycles per year operating 24/7. They are ideally suited for larger powertrain installations where uniformity and repeatability are essential to part quality and delivery is paramount. Higher volumes, expansion or ramping production can be met by integrating duplicate cells. The Continuous Flow Vacuum Impregnation technology enables continuous production through lean manufacturing.
Top Loading vs. Front Loading vs. Continuous Flow Vacuum Impregnation Systems
System
Workload Size
Process
Cycle Time
Use
Labor
Floor Space Requirement
Top loading batch system
24-96 inches in diameter; working depths of 12-120 inches
DVP, DV or W
20-40 minutes
Jobbing and processing hundreds of unique parts, large and small
High
1.000 to 10.000 square feet, including storage and support equipment
Front loading system
Rectangular tote size of 300 mm x 400 mm x 800 mm
DVP or DV
240-540 seconds
Specialized, similar parts, large and small
Low
Low
Continuous flow system
Rectangular tote size of 300 mm x 400 mm x 800 mm or direct part handling
Is it more cost-effective to repair your existing vacuum impregnation equipment or to purchase a new system? There are many factors to consider when making this decision.