vacuum system for helmet production of upgrade

The helmet industry has developed to this day, and the forming process of helmets requires the use of vacuum technology. The cut helmet material – usually PC (polycarbonate), is heated to a certain temperature, then vacuum bonded to the mold and cooled to shape. The work pressure is usually around 350mbar (abs).

For example, at first a helmet company used 15 vacuum forming machines, each of which was equipped with an oil lubricated rotary vane vacuum pump, with motor power ranging from 1.1-2.2KW. After years of use, the problem for users is that multiple oil lubricated vacuum pumps require at least two shutdowns for maintenance each year. However, after a few years of use, the frequent failures of these pumps have an increasing impact on production, and the cost of accessories and maintenance is also increasing. Secondly, the noise and heat emitted by these 15 vacuum pumps also affect the environment of the production site. The factory also has higher requirements for sewage discharge, so we hope to solve these problems at once through renovation and upgrading.

EVP has proposed a solution: an oil-free claw vacuum pump system.

Centralized vacuum (central vacuum) is an ideal solution when multiple ends are simultaneously using vacuum and the working pressure is around 350mabr. Its advantages lie in:

1. Energy saving. By utilizing the peak valley vacuum at the end and reducing the excess of a single pump configuration, the total flow rate can be significantly reduced, thereby achieving the goal of energy conservation.

2. Reducing the number of pumps is beneficial for centralized management and maintenance. In reality, many customers have configured multiple pumps of different brands and models for the same purpose, which brings great difficulties to daily management. By changing to a central vacuum system, the workload related to maintenance and accessories has been greatly reduced.

After the vacuum pump is concentrated in one place, both noise and heat emissions are effectively controlled, and the impact on the working environment is almost negligible.

The installation of this oil-free claw vacuum pump system brings obvious benefits to users:

1. The total power of the vacuum pump has been reduced from 22.5KW to 13KW, which means saving about 10 kWh of electricity per hour. Helmet Company operates for 320 days per year and operates for 16 hours per day, with a rough calculation of 51200 kWh per year.

2. The number of vacuum pumps has been reduced from 15 to 2. The maintenance work of shutting down 15 vacuum pumps twice a year has been reduced to a minimum, and only regular observation of the oil level of the vacuum pumps is required.

3. Save at least 18000 yuan annually in maintenance costs. (The cost of downtime loss and maintenance labor, as well as the cost of environmental waste disposal, has not been calculated). The new vacuum pump has a maintenance cycle of up to 10000 hours. For a cross speed company, it is equivalent to maintaining it only once in the past 2 years, and the maintenance only involves replacing the gearbox oil – the cost is only a few hundred yuan.

4. Solved the problem of noise and waste discharge. The new vacuum system is located in an open corner of the workshop, without the need for a dedicated machine room or soundproofing facilities, and the pump noise is almost imperceptible in the production area. The pump chamber of the oil-free claw vacuum pump is completely oil-free, so the exhaust is completely pollution-free and can be directly discharged outdoors without any treatment. The problem of treating the waste oil and filter element generated by the oil lubricated vacuum pump before no longer exists.

The new vacuum system has been running continuously for over 18 months. For the original choice, it was very correct: the new vacuum system is very efficient, with a short investment return period, completely exceeding the expected effect.