DESCRIPTION

Car dashboard (panel facing the driver of a vehicle) are most often covered with artificial leather, which is made from a PVC-based powder that melts into a pre-heated negative form. Before removing the artificial skin, the mold has to be cool down. The cooling system consists of central booster stations, suction and pumping units for each automotive production line, filtration unit and hot water cooling system.

Central BOOSTER SET

The central booster pumping unit is used as a pressure source for all automotive production lines. The pressurized water is run under the ceiling of the production hall in the PPR pipeline. The large approx. 200 kg dashboard mold sprayed with the vulcanized powder is placed on a cooling bath. There are placed special nozzles not just for cooling, but also for steam and water suction. After opening the valve, 400 liters of cold water will flow through the nozzles, cooling the form/mold to the desired temperature (50 °C). The mold spraying time is determined by the size of the mold and molding, the estimated amount of water is approximately 200 liters per minute. The booster pumping set cosists also two expansion vessels of 100 liters / PN16 that serve as water hammer compensators/alleviators in the long pipeline. Pumps are regulated by variable frequency drivers (for each pump one) that are located in the main switchboard. The control unit provides monitoring, recording and controling of the booster set, filtration, cooling and eventually every failures.

The AQCS 15 / 9-6x11-F-N2x100 Central BOOSTER SET contains:

• 6 pcs of vertical DPV 15/9 stainless steel pumps (flow: 0-144 m³ / hour = 2400 l / min, pressure: 8,5 bar)
• 2 pcs of 100 liter tanks PN16
• 6x frequency converter
• control unit

Suction and pumping unit

For each production line the suction and pumping unit is designed as a separate unit that ensures the pumping of the cold water into the nozzles, emptying heated water from the cooling bath and pumping it into a collecting tank. Heated water must be gone within 30 seconds. Then water filtration and cooling takes place in the cooling circuit, which must be completed and prepared within 2 to 3 minutes.

The AQCS EP70-300-8.0 suction and pumping system includes:

• control cabinet with control unit
• self-priming pump LIVERANI EP 70 (power: 5.5 kW, flow: 420 l / min, pressure: 0.5 bar)
• collecting tank with hydrostatic sensor (volume: 300 l)
• EBARA CDX 200/25 centrifugal pump (power: 2.2 kW, flow: 100 l / min, pressure: 3.4 bar)
• closing valve assembly providing cooling water supply from central booster set, adapted to remote control from the control panel of the production line

Central filtration system

The polluted cold water from the product lines is pumped into the collecting tank. Based on the level sensor signal, the pump starts pumping the water through the filter to warm water vessel, with overflow for hot water. 

The AQCS 3M40 / 200-2x5,5- Filter unit contains:

• collecting tank (1500 liters) with hydrostatic level sensor
• 2 pieces of report containing:
  • horizontal pump EBARA 3M40 / 200 (power: 5.5 kW, flow: 500 l / min, pressure 5.1 bar)
  • automaticself-cleaning filter John Deere JDW3200-3 "
• DHW vessel with overflow for hot water
• switchboard with control unit:
  • triggers and stops filtering based on a hydrostatic sensor signal
  • monitors and triggers automatic filter cleaning
  • report a malfunction to a central booster set control panel (cabinet)

Cooling system

There is self-cooling pumping set, which based on the sensor signal in the central cooling vessel, initiates the cooling process. The core of the pumping unit is the vertical stainless steel pump DPV 10/4, which sucks water from the warm portion of the central vessel and pushes it through the heat exchanger into the cold portion of the central vessel. To ensure a defined flow and temperature of cold water, the pump is also on the cold water branch. 

Cooling pumping unit AQCS 10/4-6x1,5-B 12(28) consists:

• 3 pcs of vertical stainless steel pumps DPV 10/4-1,5kW on the cooling water side (3x120l/min at 3 bar)
• 3 pcs of vertical stainless steel pumps DPV 10 / 4-1,5 KW on the cold water side (3x120l/min at 3 bar)
• 3 pcs of heat exchanger B12 or B28
• switchboard with control unit:
  • triggers the overcooling on the basis of the signal from the temperature sensor
  • checks the status of the unit
  • eventually report a failure to the central booster set control panel