Surface processing - Cyklos

Surface processing has traditionally been physically kept separated from machining. The size of the installations and buildings, the safety requirements and the environmental hazards of the chemical processes refrained workshops, with a few exceptions,  to invest in and operate surface processing equipments nearby in-line with machining. However prior deliveries, most of the finished parts go through a surface processing step (anodizing, phosphating, electroplating…). As a consequence, an interruption in the manufacturing flow of finished parts remains until today, increasing lead time, logistic costs and defects. Tornos tackles these three points simultaneously and enables a continuous manufacturing flow with the Cyklos solution, a unique technology com-bining a surface processing equipment and process in a compact, zero reject, high performance and low cost of ownership tool.

Technology

Cyklos concept is based on a patented technology owned by Tornos in which parts are transported from bath to bath and inside each bath automatically via a simple combination of translation and multiple rotations along the same axis of small carriers on which the parts are attached to. As typically hundred parts can be loaded on each carrier and a carrier can enter the machine every two minutes, the machine throughput can continuously process parts at a rate of one part per second. As each carrier undergoes the exact same processing sequence that the next or the previous carrier and since the process is (chemicals, temperature, voltage,…) entirely computer controlled, the stability of the processing performances is ensured. As the carrier perform several complete rotations in the processing baths, there is no gas remaining in the parts and the non uniformities of the current lines of the electro-chemical process are fully averaged. Hence, this technology achieves an unprecedented combination of productivity, stability, quality and uniformity.

Moreover, the carriers remaining always either inside the baths or just above the liquid surface, a very efficient and cost effective trapping of vapors from the bath is enabled. In addition, the cross-contamination from bath to bath is drastically reduced by the rotation of the carriers and the large surface ratio of parts over carrier.

It is therefore possible to filter and trap all hazardous vapors and waste inside the machine so that it can be operated with zero reject on site. Indeed, the machine can be installed in a machine shop with only electricity, compressed air and water inlet and without any connection to the drain.

Integrating all key process steps like surface preparation (degreasing, activation,…) surface processing (anodisation, plating, phosphating, deburring…) rinsing and drying then becomes possible in a highly efficient and compact tool : as each Cyklos tool is dedicated to one surface processing, each step can be streamlined and highly integrated With carriers to transport the parts throughout all steps, the Cyklos tool has the flexibility to process different parts sequentially either with identical carriers or carriers with adapted part fixtures depending on part design.

As a conclusion, the Cyklos technology embedded in a compact and dedicated housing has all it needs to perform with superior performances in the workshops most of the surface processing traditionally made in very large and remote installations.

More informations www.cyklos.com