Patent Application
20230031985
The present invention relates to post-manufacturing systems and methods, and more specifically, to systems and methods of loosening, removing and collecting debris from newly machined articles using compressed air.
Machining is a subtractive manufacturing process through which raw materials are converted into finished products by the controlled removal of unwanted material from a workpiece. The machining process creates large and small particulates, for example fragments of raw materials and disintegrated coating dust, which can settle on the newly machined article. Additionally, newly machined articles are typically oiled as oil and water-based flood coolants are used in the machining center’s cutting process, thereby creating a layer of viscous debris on the machined part.
Compressed air is used to remove oil particulates and or fluid coatings from the recently machined part. Due to the high air pressure being sprayed into the part, droplets of oil are aerosolized and are “blown off” into the ambient factory air. These small particulates of oil remain in the air and can be inhaled by the machinist and other factory workers. This cleaning process with compressed air also causes larger sized oil droplets and metal fragments to scatter and collect onto nearby machinery, people and other items, creating a slippery floor for example. An oil film residue with small metal chips remains in the area and is potentially hazardous.
In order to overcome the safety hazards associated with aerosolizing hazardous liquids and dispersing particulates it is possible to use compressed air in a controlled environment, for example by employing an exhaust hood. This accommodation is undesirably cumbersome because either the machined parts must be transported to the hood, or the hood must be located near where the machining takes place, which requires electricity and a lot of space.
As can be seen, there is a need for systems and methods that remove contaminating particulates but that do not blow particulates and/or aerosolized oil or other fluids into the environment. It is desirable that this system is easy to use, portable, and doesn’t require a power source such as electricity.
A portable debris removal system is particularly well suited for cleaning newly machined parts. The system generally includes an enclosure assembly where a user cleans a machined part with a compressed air gun, with air within the enclosure assembly evacuated for decontamination through a series of filters. Ambient air and air gun expressed compressed air are drawn into the system via the Venturi effect created by a Venturi vent positioned on the bottom of the enclosure assembly. Contaminants such as oil, cleaning fluid and particulates are retained in one of the filters or deposited in a waste vessel. The enclosure assembly is at a height that is functional for operators, with the ability to slightly raise or lower based on the operator’s height. The system is compact, easy to use, and relies on the Venturi effect and compressed air to circulate air, thereby removing the need for an external power source such as electricity or batteries, except as may be required for compressed air source.
Specific structures are numbered throughout the various figures as follows:
As used herein, “air” and the like shall generally refer to gaseous matter including ambient air mostly comprising nitrogen and oxygen, plus various sources of compressed gaseous matter including compressed ambient, compressed pure gasses such as oxygen or nitrogen, and compressed mixtures of gas.
Referring to
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Funnel 24 rests upon the bottom wall of enclosure body 22 and facilitates pulling ambient air down through Venturi vent 70 and into the system. Grate 23 sits atop funnel 24 and prevents machined parts from inadvertently dropping into enclosure body 22.
Enclosure filter 26 absorbs spray deflection during system use and is preferably positioned on back wall 27. In a preferred embodiment enclosure filter 26 is a mesh filter approximately 15.5” by approximately 9.5” by approximately 0.75” and is held in place by enclosure filter frame 25.
The Venturi effect is the reduction in fluid pressure that results when a fluid flows through a constricted section of a pipe. In the present invention Venturi vent 70 facilitates the Venturi effect, thereby creating the negative pressure to draw air both expressed from air gun 40 and from ambient air flow 82, into the system. Referring to
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Stage one is wet sock filter 52, which is preferably a felt filter bag of trade size 4, having dimensions of approximately 4" in diameter by approximately 14" long with a 50 micron rating. The bag filter is most preferably constructed of NOMEX plastic and felt for use with oils and hydrocarbon solvents, with a commercially available example being McMaster-Carr Part # 51635k211.
Metal fragments and debris accumulate at the bottom of the wet sock filter 52, but smaller sized debris, oil and cleaning fluids pass through the wet sock filter and down into waste vessel 60. Notably, the large surface area of the wet sock filter, preferably approximately 4" × 14", or 201 cubic inches, does not impede the flow of air as debris gets trapped inside.
Air passing through stage one builds up in waste vessel 60, thereby creating positive air pressure which causes post-stage one air to travel upwardly from waste vessel 60 and into stage two filtration, which is inner filter 54. Inner filter 54 is preferably a foam-based filter that removes thinner viscosity oils commonly cleaned off recently machined parts, as well as collects some smaller metal debris. In a preferred embodiment inner filter 54 is an open cell neoprene blue foam that is approximately ¼” thick, with a commercially available example being McMaster-Carr Part # 8570K13.
Post-stage two air goes through outer filter 57, which is stage 3, before being released into the ambient factory air. Outer filter 57 is preferably a circular air filter with paper and fabric fins on the sides having a metal top with an approximately 3.03" round opening through which exhaust tube 28 is inserted, and having an outer diameter of approximately 12.11". It is further preferred that outer filter 57 is constructed of 80/20 cellulose/polyester and exhibits 99.9% efficacy at 0.6 microns. A suitable outer filter is commercially available from Damn Filters of Wichita, Kansas.
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It should be understood that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims. Examples of modifications include using the system in semi-automated or fully automated manufacturing environments. Also, the air nozzle can be stationary and activated with the foot pedal, either with or without the air gun. Also, the operator / robotic arm can hold the part under the fixed air nozzle to clean off the part.
Terms such as “substantially” and the like shall mean within reasonable bounds when considering limitations such as machines, materials, manufacturing methods, and people. By way of example, a “substantially smooth” surface means there are no intentional bumps or irregularities. All ranges set forth herein include the endpoints as well as all increments there between, even if not specifically stated. By way of example 1 to 2 inches includes 1 inch, 1.000001 inches and so forth. Finally, unless otherwise stated or contrary to common sense, “approximate” and the like shall mean +/-10%.
This application claims the benefit of U.S. Provisional Pat. Application number 63/226,232 entitled SYSTEM AND METHOD OF LOOSENING, REMOVING AND COLLECTING DEBRIS FROM NEWLY MACHINED ARTICLES USING COMPRESSED AIR , which was filed Jul. 28, 2021. This provisional application is incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63226232 | Jul 2021 | US |
