Improvement of the Cyclone Extraction System on the Elhaus Saw

In today's manufacturing environment, innovation and adaptability are frequently required when seeking solutions that achieve higher quality and greater productivity in the production of the final product.

Solution and Method

In today's manufacturing environment, innovation and adaptability are frequently required when seeking solutions that achieve higher quality and greater productivity in the production of the final product. Most products go through various processing procedures to achieve the desired product characteristics, but this also increases the amount of waste, as multiple different machining operations performed on the product always increase the possibility of errors or damage. Manufacturing is characterised by companies receiving orders randomly in relation to customer needs and depending on the market itself.

In the automotive industry, the "just in time" system is typically used. The product is delivered to the company exactly when it is needed and is not stored, thereby gaining considerable storage space, which represents a major logistical challenge for all companies that manufacture such products. Impol produces most of its final products for the automotive industry, so the company is always in a time and logistics battle, where the most important thing is that orders are produced on time, to the highest possible quality standard and, of course, in appropriate quality.

Aluminium today is among the most sought-after metals in the world. The metal is found in the vehicle industry, currency, construction, musical instruments, electrical conductors, household appliances, packaging and others. In the diploma thesis, he will explain how Impol transforms aluminium alloys into rods and profiles.

He will focus his attention on the cyclone extraction system on the Elhaus machine saw, which is part of the 55 MN direct extrusion press. He does not work at this workstation himself, but participated in the optimisation of this machine tool in a small team dedicated to solving problems with aluminium chip extraction as quickly as possible. The key purpose of his work is to present how they reduced downtime, improved product quality and improved workplace safety.

This project was carried out together with the operators of this machine, with whom they tested various solutions that would improve the extraction system. In this project, they tested the effectiveness of a new type of saw blade, with which they achieved better cutting quality. They improved the TPM activity implementation system and thereby enabled long-term relief for the machine operator.

With various upgrades to the saw in combination with the new saw blade and the upgrade of TPM activity implementation, they drastically reduced downtime and costs associated with machine maintenance.