PU-Coated Ceramic Filter
From the Idea to the Series Component in Record Time
In mid-2016, Nanostone Water GmbH, Halberstadt, Germany, approached the polyurethane specialist Hennecke, with an unusual task. To seal the end face of a ceramic industrial filter with polyurethane and/or polyurea. The challenge of the project consisted in not sealing the many nano-coated inflow channels, but only wetting the bridges between them. In this way, the otherwise unprotected bridges can withstand abrasive or chemical attack from the medium being filtered for longer, and significantly increase the filter lifetime. A simulation reveals the key role of the surface tension.
Hennecke GmbH, Sankt Augustin, Germany, took on this task and, together with Nanostone, simulated the spray clearances, discharge rates and robot processing rates. From this, the assumption emerged that the surface tension of the material could be the key to solving the task. To verify this theory in practice, experiment were then carried out at the tech center.
The Microline high-pressure dosing machine with robot-guided MN6 spray mixing head was used for this, which can precisely dose even small amounts. Right from the first shots, it proved very promising and confirmed the desired physical effects.
It was even possible to process two different systems and so determine their specific advantages and disadvantages. Within the test period, the best processing parameters were determined and some prototypes were produced for further tests and a field trial.
From Order to Series Production in One Year
The results finally obtained exceeded the expectations, so that Nanostone Water subsequently invested in a production line. After less than six months, Hennecke had produced the line, assembled it at Nanostone and integrated it into the synchronized series production there. In less than two years, an idea and the initial contact had resulted in a production line for a series component.
Hennecke Tech Center
At its headquarters in Sankt Augustin, Germany, the mechanical engineering company Hennecke operates a pilot plant covering over 1000m². Here, applications engineers operate various types of machine, on which interested customers can develop or improve their own parts.
In this way, prototypes for preliminary series can be produced, initial trials with new products run or existing products from other manufacturing processes transferred to polyurethane. Process engineers are also integrated in the development process, and perform simulations or calculations where required.
Moreover, existing machines in the tech center are enhanced and new machines constructed, tested and made ready for series production
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