Patented, hybrid cleaning methodology deploying cavitation effect

Cleaning method deployed in CoolingCare devices is based on the patented method of two-way pulsation of the cleaning medium. HYDRAULIC SHOCK WAVES GENERATE A CONTROLLED CAVITATION PHENOMENON THAT INITIATES THE PROCESS OF REMOVING SCALE AND RUST FROM THE CHANNEL SURFACE. Rapid compression and expansion of the liquid in the channel causes local pressure drops, resulting in the formation of thousands of cavitation bubbles. Cavitation cleaning is supported with a water-based cleaning solution, which additionally supports the dissolution of deposits on the channel walls. Unlike other technologies, where the cleaning method is based on pumping aggressive cleaning agents through the mold cooling circuits, the hydromechanical, hybrid cleaning method using the cavitation effect taking place inside the channel quickly and effectively removes limescale deposits mechanically, allowing the use of less aggressive, safer cleaning agents. After cleaning, the channels are automatically rinsed with water and dried with compressed air.

The use of the hybrid pump / cavitation generator method allows to obtain high turbulence of the flow of the cleaning liquid and thus reduces the cleaning time. The patented method of cleaning using the 'water hammer’ phenomenon is the only one on the market that enables unblocking completely clogged channels.

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The device has been designed to minimize operator involvement. The operator’s tasks are limited to creating a new project or selecting one from the database, connecting the channels to the machine, choosing the cleaning algorithm, and pressing the START button. Automation, combined with advanced algorithms, allows the machine to execute a sequence of operations and also make autonomous decisions regarding whether to stop or continue the process for each section individually. This way, we are able to free up a significant amount of the operator’s time, allowing them to focus on other tasks while the machine independently performs comprehensive cleaning, diagnostics, and tool maintenance.

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It’s not uncommon for molds that require cleaning to be worth hundreds of thousands of euros. Coolingcare machines are equipped with dozens of sensors and safety algorithms that monitor the process in real time, ensuring stability of the process. In the case of sudden, unexpected event, such as i.e. leakage, the computer stops the cleaning process and notifies the operator.

Here is a list of all safety modules installed in CA units:

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A separate, dedicated feed pump for every channel ensures greater efficiency and dynamics of cleaning. Many cooling channel cleaning systems on the market are equipped with a single feed pump. Such a solution creates many inconveniences that should be kept in mind when choosing a machine for channel maintenance. These include:

Device efficiency – the more cleaning sections the device has, the more channels we will be able to connect to it at the same time, maintaining an independent and repeatable dynamics of the cleaning process. Having said that, we need to remember that feeding multiple channels with a single pump connected to a manifold will give different results compared to a situation where we have individual channels connected to sections fed by a dedicated pump. 

Cleaning time – Time savings we achieve by connecting several channels to one cleaning circuit is illusionary, because such a connection always generates much higher pressure drops, directly affecting the amount of liquid that we are able to pump in a given unit of time, and which has a direct impact on effectiveness cleaning. This is particularly important for single-pump devices, as cleaning efficiency in this type of design depends precisely on the ability of the system to pump as much liquid as possible. In practice, connection of cooling circuits in series requires a significant extension of the cleaning time, at the same time giving no guarantee that all lines will be cleaned equally. Individual connection of channels gives us much greater possibilities of monitoring and controlling both the dynamics of the process, as well as the assessment of its effectiveness.

Measurement of the flow rate – In the case of a single-section device to which the channels are connected in series, the performed flow measurement will not inform the user about the actual flow improvement for individual circuits, but only about the sum of flow rates, which can be compared 'before and after’ the process. The user will not be able to tell what increases in flow rate values were achieved and whether all channels were actually cleaned to the same degree.

Leakage detection – The bridging of the system has one more, very significant disadvantage. In the event of a leakage, we are often unable to precisely determine which channel has caused it. When we connect the channels individually, finding the cause of the leak is much easier.

This post Independent cleaning sections first appeared on Coolingcare.eu and is written by testadmin

The cleaning time of the individual cooling channels may and should differ from each other, taking into account the fact that each of the channels often has a different diameter, geometry and length, which affects the generated pressure losses and therefore the cleaning time. Therefore, the method of setting the same cleaning time for all channels, which is often used by manufacturers of devices for cleaning cooling channels, is very imprecise. Assuming all the channels will be equally clean after the same cleaning time is just wishful thinking, which can be far from their actual condition.

COOLINGCARE CA2 and CA6 are the only devices that allow users to define a flow rate reference value as a benchmark for future cleaning. In the case of a new tool, a machine operator measures the flow rate values of the individual channels and saves them ​​in a database. When the mold goes back for maintenance, the operator specifies a target percentage of the original flow rate to be achieved. The machine then begins the process and monitors the flow rate. After reaching the desired flow rate, the cleaning process ends, and the operator is informed about in the result with a text message sent to his phone number. In a case of an old tool, a machine operator selects „clean to stable result” option. The machine then measures the flow rate changes of individual channels at regular intervals, creating a curve showing the gradual increase in flow. At some point, the curve starts to level off, which will indicate that the maximum flow rate has been reached. When two successive results are similar, the machine stops the cleaning process and informs the operator with a text message that cleaning is complete. The operator can then save the flow rate as a reference for the future.

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