在高端裝備制造領(lǐng)域，重型鑄件因結(jié)構(gòu)復(fù)雜、尺寸龐大，其內(nèi)腔及交叉孔隙的毛刺與殘渣清理始終是行業(yè)難題。專用高壓去毛刺清洗機通過創(chuàng)新流體動力學(xué)設(shè)計與智能化控制，實現(xiàn)了對鑄件微米級殘渣的高效去除，顯著提升了產(chǎn)品合格率與生產(chǎn)節(jié)拍。

　　In the field of high-end equipment manufacturing, the removal of burrs and residues in the inner cavity and intersecting pores of heavy-duty castings has always been a challenge due to their complex structure and large size. The dedicated high-pressure deburring cleaning machine achieves efficient removal of micro scale residues in castings through innovative fluid dynamics design and intelligent control, significantly improving product qualification rate and production cycle.

　　高壓水射流技術(shù)突破

　　Breakthrough in High Pressure Water Jet Technology

　　設(shè)備核心采用超高壓往復(fù)式增壓系統(tǒng)，可將自來水加壓至300-500MPa，形成直徑0.1-0.3mm的聚焦水射流。該射流在特定噴嘴作用下產(chǎn)生空化效應(yīng)，水滴以超音速沖擊鑄件表面，對硬度達HRC50的殘渣實現(xiàn)剪切剝離。某航空發(fā)動機機匣清洗實驗顯示，單次作業(yè)殘渣去除率達98.6%，較傳統(tǒng)工藝提升3倍效率。

　　The core of the equipment adopts an ultra-high pressure reciprocating pressurization system, which can pressurize tap water to 300-500MPa, forming a focused water jet with a diameter of 0.1-0.3mm. The jet produces cavitation effect under the action of a specific nozzle, and water droplets impact the surface of the casting at supersonic speed, achieving shear peeling of residue with a hardness of HRC50. The cleaning experiment of a certain aircraft engine casing showed that the removal rate of single operation residue reached 98.6%, which is three times more efficient than traditional processes.

　　多軸聯(lián)動精準(zhǔn)操控

　　Multi axis linkage precise control

　　針對復(fù)雜型腔結(jié)構(gòu)，設(shè)備配置六軸聯(lián)動機械臂，結(jié)合激光掃描建模技術(shù)，可自動生成最優(yōu)清洗路徑。機械臂重復(fù)定位精度達±0.05mm，確保水射流精準(zhǔn)穿透直徑3mm的深孔。在某重型燃氣輪機葉片清洗中，該系統(tǒng)成功清除隱藏在1.2米深流道內(nèi)的氧化皮，較人工清理時間縮短85%。

　　For complex cavity structures, the equipment is equipped with a six axis linkage robotic arm, combined with laser scanning modeling technology, which can automatically generate the optimal cleaning path. The repeated positioning accuracy of the robotic arm reaches ± 0.05mm, ensuring that the water jet accurately penetrates deep holes with a diameter of 3mm. In the cleaning of a heavy-duty gas turbine blade, the system successfully removed the oxide scale hidden in the 1.2-meter deep flow channel, reducing the cleaning time by 85% compared to manual cleaning.

　　旋流分離與循環(huán)過濾

　　Cyclone separation and circulating filtration

　　為解決殘渣回收難題，設(shè)備集成三級旋流分離裝置。含渣水流經(jīng)一級切向入口產(chǎn)生螺旋運動，在離心力作用下，粒徑大于50μm的顆粒被甩至錐壁并沉淀。二級聚結(jié)濾芯采用梯度孔徑設(shè)計，逐級攔截微米級殘渣。三級反滲透膜過濾系統(tǒng)則確保循環(huán)水清潔度達NAS 6級，實現(xiàn)95%以上的水資源循環(huán)利用。

　　To solve the problem of residue recycling, the equipment integrates a three-stage cyclone separation device. The slag containing water flows through the first tangential inlet to generate spiral motion. Under the action of centrifugal force, particles with a diameter greater than 50 μ m are thrown to the cone wall and precipitate. The secondary coalescing filter adopts a gradient pore size design to intercept micron sized residues step by step. The three-stage reverse osmosis membrane filtration system ensures that the cleanliness of the circulating water reaches NAS level 6, achieving over 95% of water resource recycling.

　　智能檢測與閉環(huán)控制

　　Intelligent detection and closed-loop control

　　清洗過程搭載聲發(fā)射檢測模塊，通過分析殘渣剝離產(chǎn)生的聲波信號，實時判斷清洗終點。當(dāng)特征頻段信號幅值衰減至閾值時，系統(tǒng)自動切換至柔性沖洗模式，避免過洗損傷基體。某汽車變速箱殼體生產(chǎn)線數(shù)據(jù)顯示，該閉環(huán)控制使單件清洗能耗降低40%，同時將表面粗糙度控制在Ra1.6μm以內(nèi)。

　　The cleaning process is equipped with an acoustic emission detection module, which analyzes the sound wave signals generated by residue peeling to determine the cleaning endpoint in real time. When the amplitude of the characteristic frequency band signal decays to the threshold, the system automatically switches to flexible flushing mode to avoid damage to the substrate caused by over washing. According to data from a production line for a certain automobile gearbox housing, this closed-loop control reduces energy consumption for single cleaning by 40%, while controlling surface roughness within Ra1.6 μ m.

　　環(huán)保與安全設(shè)計

　　Environmental Protection and Safety Design

　　設(shè)備采用全封閉防爆結(jié)構(gòu)，清洗艙體耐壓等級達1MPa，配備可燃氣體濃度監(jiān)測與自動泄壓裝置。廢水處理系統(tǒng)通過芬頓氧化與活性炭吸附，使化學(xué)需氧量（COD）排放濃度低于50mg/L，滿足國家一級排放標(biāo)準(zhǔn)。在某風(fēng)電軸承制造企業(yè)應(yīng)用中，年危廢產(chǎn)生量減少200噸，環(huán)境效益顯著。

　　The equipment adopts a fully enclosed explosion-proof structure, and the pressure resistance level of the cleaning compartment reaches 1MPa. It is equipped with combustible gas concentration monitoring and automatic pressure relief devices. The wastewater treatment system uses Fenton oxidation and activated carbon adsorption to achieve a chemical oxygen demand (COD) discharge concentration below 50mg/L, meeting the national first-class discharge standard. In a wind power bearing manufacturing enterprise, the annual hazardous waste generation was reduced by 200 tons, resulting in significant environmental benefits.

　　應(yīng)用場景拓展

　　Application scenario expansion

　　該設(shè)備已成功應(yīng)用于核電主泵殼體、礦山機械液壓閥塊等高端鑄件加工。某企業(yè)實踐表明，針對交叉孔隙率達35%的復(fù)雜鑄件，清洗節(jié)拍從傳統(tǒng)工藝的4小時縮短至25分鐘，產(chǎn)品一次交檢合格率從72%提升至99%。隨著3D砂型打印技術(shù)的普及，設(shè)備正拓展至增材制造鑄件的后處理領(lǐng)域。

　　This equipment has been successfully applied to high-end casting processing such as nuclear power main pump casing and mining machinery hydraulic valve block. Practice in a certain enterprise has shown that for complex castings with a cross porosity of 35%, the cleaning cycle has been shortened from the traditional 4-hour process to 25 minutes, and the first-time inspection pass rate of the product has increased from 72% to 99%. With the popularization of 3D sand printing technology, equipment is expanding into the post-processing field of additive manufacturing castings.

　　重型鑄件專用高壓去毛刺清洗機通過高壓水射流、智能控制與環(huán)保技術(shù)的深度融合，重新定義了精密鑄件清洗的技術(shù)標(biāo)桿。其高效除渣能力不僅解決了行業(yè)痛點，更為智能制造時代的鑄件品質(zhì)升級提供了關(guān)鍵裝備支撐。

　　The heavy-duty casting dedicated high-pressure deburring cleaning machine redefines the technical benchmark for precision casting cleaning through the deep integration of high-pressure water jet, intelligent control, and environmental protection technology. Its efficient slag removal capability not only solves industry pain points, but also provides key equipment support for the upgrading of casting quality in the era of intelligent manufacturing.

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