Automatic Precision Tube
Cleaning System is Ideal for Validation
This fully automated system is designed for
high production precision cleaning,
precision rinsing, overflow rinsing, and drying of medical tubing in batch quantities.
It rapidly processes tube bundles of various lengths and IDs vertically loaded into circular basket
(see below). It is a continuous feed system that simultaneously processes and
transfers multiple baskets.
The photo below is of the front
of the machine showing stainless steel automation guard and RamNet operators control pedestal (to the left).
DYNAMIC FLOW COMBINATION - the RAMCO
DIFFERENCE
The heart of the system is the adroit use of
process elevators within each chamber. The elevators are used to transport
baskets into and out of each chamber. However, the most important function of
each elevator is to position and gently move the tubes up an down
during the process. It is this function that allows RAMCO systems to achieve superior results in washing, rinsing and drying.
We call it Dynamic Flow Combination. The effects of Dynamic Flow Combination
are better coverage of component surfaces, more consistent results, and accelerated processing times.
AUTOMATION
Baskets are positioned between two sensors on
a loading conveyor section. The operator simply presses a start button on the conveniently located control panel and the system takes over from there. It automatically indexes,
precision washes, precision rinses and completely dries each basket of tubes. The transfer system uses multiple arms to allow for simultaneous indexing of
multiple baskets. The consistency delivered by the automation enhances part quality and reduces failures down the assembly/test line. The steps are PLC controlled with dual
phases within the precision washing and rinsing stages sequencing powerful ultrasonics
with turbo/agitation.
PROCESS
- TURBO/AGITATION WASHING WITH ULTRASONICS
The unique RAMCO ultrasonic system cascades
powerful sweep frequency (between 38 to 42 kHz) ultrasonics with our
standard turbo/filter/agitation washing. Using mechanical agitation washing to
remove gross contamination and ultrasonic cleaning to remove finer and/or more
resistive deposits is a very effective processing routine.
TURBO/AGITATION WASHING
Agitation washing is
enhanced when used in
conjunction with a TurboFilter System.
The Turbo/agitation phase is produced using a high volume all stainless steel
pump, closed looped manifolds, and multiple injectors to direct an even flow of
turbulent solution through the tubes. The solution is filtered and the flow is
adjustable. Turbo/agitation is uses to removes gross contaminants and oil.
RAMCO turbo systems are proven to accelerate processing
time in washing and/or rinsing.
ULTRASONICS
The ultrasonic cleaning phase removes the finer and/or more resistive contaminants
from the inside of the tubes. MultipleRollover is incorporated to repeat
the dual phase sonic/turbo-agitation process for a preset number of “rollovers”.
The RAMCO ultrasonic system provides superior ultrasonic washing action over conventional (static) systems by
dynamically moving the work through the processing zone. The result of this
routine is faster and very effective processing. The ultrasonic stage can also
be set to provide continuous vertical oscillation of the work during the sonic
cycle. A selector switch is provided for static ultrasonic or oscillating
ultrasonic modes.
Following precision washing the parts are automatically
transferred to the precision rinse stage. The rinse process also includes
alternating cycles of agitation with turbulation and powerful ultrasonics.
Following precision rinsing the parts are automatically transferred to the final
overflowing DI rinse stage. Following rinsing the parts are transferred
to a very effective the hot air knife dryer.
PROCESS CONTROL
The machine is built with RamNet
microprocessing system. This pattern is repeated. Following rinsing
the parts are transferred to the hot air knife dryer An Allen-Bradley MicroLogix microprocessor is used
to control each stage. The microprocessor controls the timing, sequencing, all
solenoids relating to covers, elevators, pumps, ultrasonic generators and heat.
A large color touch screen is located in the Operators Control Station. Each
step of the process is PLC controlled.
Key validation items are set and accurately
monitored. Any fault in the system is immediately reported within the PLC
program (see fault screen below) with an external visual stack-light alarm (see
top system picture). The process will not continue to run when any fault is
detected. Temperature high and low limits, sonic power limits, and all points of
the machines function are monitored.
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