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Magnetic Filtration Systems
Sub-micron filtration for industrial fluids in precision machining & wash system applications
£
CO 2 e
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When precision counts, Eclipse delivers...
Contents
Who We Are
p4
Introduction to Eclipse Magnetics
Magnetic Filtration Introduction
p5 - 7
Save time, save money, minimise waste
Testimonials
p8 - 9
Hear what our customers have to say about magnetic filters
Typical Applications
p10 - 11
How our products can solve problems & add value to your business
Product Range Find the right solution for your application
p12 - 23
Installation & Technical Data Typical installation points & useful information
p24 - 25
100 years of innovation
Innovation in magnetics Our magnetic technology is widely used at leading worldwide companies and in major development projects, all requiring a guarantee of equipment performance. Serving some of the leading names in industry
Designing excellence ` We have a track record of producing high quality products backed by a commitment to total customer satisfaction. Our technical application teams have a wealth of experience, thus ensuring many of our products are market leading innovations. All manufacturing is carried out under an ISO 9001 certified quality management system and we are accredited to ISO 14001 environmental standards. Unrivalled product range We serve worldwide markets with an extensive product range including filtration systems, foreign body removal systems, magnet assemblies and complex magnetic industrial equipment used in industries such as automotive, aerospace and nuclear. Many of our products are unique and are covered by global patents. Worldwide support ` We offer worldwide support through our offices in the UK, Canada and China. We also have employees in various territories and a network of technically trained partners to provide local product support.
JCB Caterpillar NSK Denso Perkins Geely
BMW Ford Bosch Honda Bombardier Volvo
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Magnetic Filtration | Innovative Magnetic Solutions
Driving competitive edge into precision processes
Our patented magnetic filtration systems are the ultimate in filtration technology, providing cost, quality and environmental benefits.
Magnetic filtration operating principle Magnetic filtration is the most effective means of removing problem ferrous particles from industrial fluids such as coolants, lubricants and wash solutions. All the benefits of Eclipse Magnetic filters are based on their ability to remove virtually all ferrous particles, including sub-micron particles from the process. Traditional filtration systems typically leave particles smaller than 5 - 10 microns circulating in fluid causing damage to process equipment and finished products. Magnetic filtration systems are ideal for either new build projects or they can be fitted to enhance existing filtration systems.
Significantly lower operating costs Longer lasting fluids extends fluid life by x10 Magnetic filters can remove particles smaller than one micron in size. These particles significantly affect the performance of fluids and also act as a focus for bacterial build up. NO consumables - Cuts filter costs by up to 100% Unlike other types of filtration, once magnetic filtration is installed there is nothing else you need to buy to ensure effective filtration over the filter’s lifetime, which can be typically greater than 20 years. Minimal fluid loss Contamination is removed from the filter as a semi-dry ‘cake’. Fluid loss is considerably less than that of traditional filter media. NO disposal costs The cake itself can be recycled, eliminating expensive specialist disposal costs. Minimal running costs - Virtually zero Manually cleaned magnetic filters require no additional power. Magnetic self-cleaning filters only require a small amount of power for the cleaning process. Ideal for 24/7 operation - Increase productivity Fully automated magnetic filtration systems are ideal for continuous manufacturing lines. Rapid return on investment Magnetic filtration is perfect for cost reduction and continuous improvement programmes providing a rapid return on investment. Health & safety Minimal handling of contaminated fluid and bacterial growth.
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Innovative Magnetic Solutions | Magnetic Filtration
Increase Productivity
Maintain flow rates High flow rates can be maintained without affecting filtration efficiency. Fluid does not flow through filter media, so flow is uninterrupted. Flow rates are determined by your process requirements, not by your filter. NO back pressure Even when the filter is ‘full’ there is no blinding or risk of burst filters, reducing downtime. Reduced wear / Increased precision finish Particles that pass through traditional filters act as an abrasive, wearing parts, machinery and product. Magnetic filters remove these damaging particles. Fine filtration Conventional filtration media, at 5 microns and below, can strip oils of anti-foaming, anti-bacteria and other additives. Magnetic filtration enables sub-micron filtration without affecting the oil’s properties, and can actually aid the effective control of bacteria.
Reduced Environmental Impact
A major consideration for any business is its responsibility to the environment. Magnetic filtration is a positive contribution to companies’ environmental policies and ISO14001 accreditation. Reduced waste Magnetic filtration requires no consumable or disposable products. It extracts virtually 100% of ferrous contamination, drastically reducing the use of disposable filter media. Less fluid is used as its effectiveness is maintained for longer. Recycled waste Ferrous particles are separated from fluid and filtration media so can be recycled rather than disposed of.
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Magnetic Filtration | Innovative Magnetic Solutions
Outperforms other filters
Magnetic filtration can be used as a replacement for, or in conjunction with other forms of filtration to optimise filtration efficiency. There are many types of filtration media, Eclipse Magnetics systems offer distinct advantages.
Typical filter type comparison
The table below shows how magnetic filtration compares to other forms of filtration in key performance criteria.
Micromag & Filtramag+
Magnetic rollers
Hydrocyclone/ centrifugal
Candle, powder
Settlement tanks
Vacuum
Autofiltrex & Automag Skid
Barrier (cartridges, paper)
Costs
very high
very high
Capital investment
medium low medium
low
high
high
Running costs
zero
zero
low
low
high
high
low low
Return on investment (years)
< 1
<1/2
2-5
5
never
10
5
10
Performance
Filtration capability (micron)
< 1
< 1
> 20
> 10
> 20
> 10
> 100
>20
very high very high
very high very high
Process accuracy
low medium medium high
low medium
Flow rates (ltrs/min.)
medium low/medium low low medium medium
Note: This is general information for guidance purposes only. Please consult Eclipse Magnetics for application specific information.
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Innovative Magnetic Solutions | Magnetic Filtration
Give your business the edge. Hear from our customers...
“Before fitting Micromag we were changing filters every few days. We invested in 4 MM5s we estimate this saves us around £28,000 annually in cartridge filter costs , not to mention the resultant downtime. Following the success we have now fitted Filtramags to our grinding machines which have cut our product reject rates to virtually zero.”
- Maintenance Engineer - Borg Warner (Turbocharger Balancing Machines)
“Micromag has paid back in just a few weeks, previously we could only take out particles of 50 micron or over, which caused the fluid channels to get plugged and drills to crash. Now I have fitted Micromag, my purchase of drill bodies has fallen by 100%. I am planning to fit Micromag to all my machines. ” - Plant Manager - Collison Goll Steel (Stock Deep Hole Drilling)
“The Double AM12 Skid has increased our efficiency. We work 24 hours a day and our 18" heads cut some big pieces of steel. Magnetic filtration has dramatically cleaned up our fluids and improved the surface finish we can offer. It extracts around 50Kg per day of ferrous waste and easily handles the flow and contamination generated by the multi-machine cell.” - Facilities Manager - Milacron Machines (Sub-Contract Machining)
“The AutoMag skid has exceeded our expectations; we are more than happy with its performance. 90% of swarf material is now being successfully removed from the oil , which is a massive improvement and results in plenty of cost savings for us.” - Works Engineer - OSL Cutting Technologies (Tool Cutting)
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Magnetic Filtration | Innovative Magnetic Solutions
“This technology is economical, reliable and efficient. I believe that magnetic filtration technology is the future. ”
“The waste removal process was taking up too much valuable time. The proper filtration system is just as, or even more important than operation speed. It saves time and money from having to stop the manufacturing process to clean the tank and repair jammed parts. The Filtramag+ is very effective for what we needed. I am truly surprised how much contamination we’re removing and how it’s improved our process. We are proud to say that there are currently 5 Filtramag+ systems installed at Fruitland Manufacturing and we are thrilled to be a part of Eclipses’ growing process” - Machine Shop Supervisor - Fruitland Manufacturing
- Jonathan Michels at MMTCI -
“Micromag’s outstanding filtration capability and short investment payback period exactly matched our needs. Since incorporating Micromag into our process our machine downtime has fallen dramatically compared to our previous filtration system and our filtration effectiveness is much better as we can extract the smallest particles.” - Facilities Manager - Honda (Engine Valve Machining (UK))
“We had a real problem with downtime as our quenching tank regularly filled up with ferrous contamination – we had to halt production and clean out the tank. Automag has been a smart investment. The automated cleaning frees up my maintenance team and we will get rapid payback through reduced process downtime.”
“When we used only barrier filtration we had a constant problem with ‘blinding’ of the honing stone due to a build-up of ferrous particles. Fitting Micromag has been a real positive step, we can now guarantee a uniform high quality finish and our reject rates are minimal .” - Operations Manager - NSK (Super-finishing of Bearing Hubs)
- Facilities Manager - Cascade (Heat Treatment of Fork Lift Parts)
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Innovative Magnetic Solutions | Magnetic Filtration
Why industries choose magnetic filtration.
Magnetic filtration is widely used in the automotive industry within OEMs and tier 1 and 2 suppliers for the manufacture of powertrain and engine components.
Automotive
Typical Application
Case study
Advantages
Company Bombardier (Austria)
• Ring & pinion gear lapping • Turbocharger balancing machines • Crank shaft gun drilling
• High precision finish • Reduced downtime • 100% effective with cast iron particles • Ideal for 24/7 operation • Flow rates up to 10,000 litres: multi-use to increase flow capacity
Application Cast iron piston bushings Process Milling and gun drilling
• Valve face grinding • Cam shaft grinding • Cylinder liner honing • Engine liner grinding • Gear cutting and finishing
Filtramag removed sub-micron particles reducing abrasive wear on tools and parts. Tool changes and product reject rates were reduced to virtually zero.
Magnetic filtration is used by some of the world’s largest bearing manufacturers to ensure sub-micron accuracy in the production of bearing components.
Bearings
Typical Applications
Case study Company Tsubaki-Hoover (Poland)
Advantages
• High precision product finish, concentricity and consistency
• Hub honing • Ball grinding • Super-finish/polishing • Ring grinding • Raceway grinding • Wash systems
Application Steel ball and rollers
• Reduced downtime • Sub-micron filtration
Process Super-finishing
• Ideal for high volume processes • Can be retrofitted to existing lines
• Rapid return on investment • Reduced waste – ISO14001
Micromag improved on 20 micron paper filters by extracting sub-micron ferrous particles. Surface finish was improved and reject rates fell dramatically.
It is vital that wash solutions are kept free from ferrous particles. Many wash systems have benefitted from installation of magnetic filtration which ensures the finished product is clean and complies with quality inspection.
Wash systems
Case study
Typical Application
Advantages
Company Permoid (UK) Application Automotive fuel tanks
• Flow rates up to 10,000 litres per minute • Filters do not degrade in wash solutions • Removes ferrous deposits from finished product • Reduces reject rates
• Rotary wash systems • Transfer wash stations • Degreasing equipment • Multi-stage washers • Spray wash stations
Process Flushing rig
Reduced product reject rates to zero, reduced disposal and purchase of barrier filters by 95%.
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Magnetic Filtration | Innovative Magnetic Solutions
Magnetic filtration can improve efficiency in most steel processing operations such as steel production, both hot and cold.
Steel processing
Advantages
Typical Applications • Steel rolling mills • Sawing machines • Steel pipe cutting • Tube threading equipment • Steel quenching tanks • Surface treatment processes • Spray bars
Case study
• Automated cleaning ideal for heavy contamination • Improved surface finish • Reduced downtime • Suitable for arduous environments • 24/7 operation
Company Steelscape (USA) Application Steel rolling and pickling
Process Surface spray system
• Roller lubrication • Final wash process • Deep hole drilling
Heavy contamination blocked barrier filters within hours. Automag extracts 12000 Kg contamination / month – reject rates have fallen to zero.
Magnetic filtration enhances performance on a variety of machine tools. It offers a competitive edge to machine tool manufacturers particularly when servicing high precision applications.
Machine tool OEMs
Typical Applications
Case study
Advantages
• Can be retrofitted to enhance existing filtration systems • Reduces machine maintenance/ downtime • Flow rates 70 to 10,000 litres per minute • 100% effective with low magnetic materials e.g. cast iron and tungsten carbide • Increases the equipment, value provides a solution for the customer
• VMC, HMC, and CNC machines • Multi-axis vertical turning centres • Grinding
Company Schaudt Mikrosa (Germany)
• Honing • Lapping • Deep hole/gun drilling • EDM machines • Laser cutters
Application CNC Manufacture
Process Camshaft grinding Reduced downtime by 50% and increased the life of grinding wheels by 30%.
High intensity magnetic filtration is the only option available to guarantee a high precision finish on tool cutting operations.
Tool cutting
Advantages
Typical Applications
Case study
Company Pro-Cut Tooling (UK)
• Enables tolerances of < 1 micron • Enables manufacture of “mirror” finish tools • Can increase the value of tools by 300% • 100% effective with low magnetic materials e.g. tungsten carbide materials • Reduces wear on grinding wheels • Ensures clear grinding contact • Ideal for 24/7 or unmanned operations • Significantly extends fluid life
• Multi axes CNC machines • Tungsten carbide drills and endmills • Radius grinding • Wood working tool superfinish • “Mirror” finish plastic cutters
Application Carbide cutting tools manufacture/repair
Process Super-finish/grinding
11 Enabled manufacture of “mirror” finish cutting tools, reduced machine cleaning downtime by 75% and extended fluid life by 250%.
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Innovative Magnetic Solutions | Magnetic Filtration
PATENTED DESIGN Micromag
Filter Housing
Tapered radial flow channels
‘Rare Earth’ high-intensity magnetic core with stainless steel cover
Lid
Compact magnetic filter, easy to clean and install, high collection capacity relative to size.
Key
Contaminated fluid Filtered fluid Magnetic flux lines
How Micromag works
Contaminated fluid enters the inlet port where flow is equally split via tapered radial flow channels which lowers the flow velocity ready for the fluid to be filtered. It then passes up the outside of the centrally mounted ‘Rare Earth’ magnetic core where contamination particles are attracted and retained.
The magnetic flux circuit geometry ensures a controlled build up of contamination so the filter can never block.
Fluid continues to flow when filter is fully loaded with contamination
Filtered fluid then flows through slots at the top of the core then down and through the centre of the core, exiting through the outlet port.
Contamination
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Magnetic Filtration | Innovative Magnetic Solutions
MM - 50 bar version
MM - 12 bar version
MM5/HP/50 | MM20/HP/50 | MM10/HP/50
MM20 | MM10 | MM5
For through-spindle coolant and pressure surge applications. Aluminium construction.
MM - 80 bar version
MM5/HP/80 | MM20/HP/80 | MM10/HP/80
For through-spindle coolant applications. Suitable for HICM Acidic/Alkaline Alumnius. Stainless steel construction.
Technical Data
B
A
MMMT - Micromag mobile
C
All the benefits of Micromag in a portable unit.
Temperature range
Dimensions mm
Flow rate Max. operating pressure Connection
Construction
Product number
A
B
C
″ BSP
ltrs/min.
bar
°C
MM5
70
12
1
5 – 50
190
95
103
SAN housing, Aluminum lid
MM10 MM20
100
12
1
5 – 50
315
100
124
5 – 50
605
100
137
150
12
1
MM5/HP/50 MM10/HP/50 MM20/HP/50 MM5/HP/80 MM10/HP/80 MM20/HP/80
70
50
1
5 – 140
247
116
125
Full aluminum construction
100
50
1
5 – 140
365
116
125
5 – 140
625
116
125
150
50
1
70
80
1
5 – 140
247
116
125
Full stainless steel construction
100
80
1
5 – 140
365
116
125
150
80
5 – 140
625
116
125
1
SAN housing, Aluminum lid Cast Iron
MMMT
10
10
1”/ ¾”
5 – 40
N/A
N/A
N/A
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Innovative Magnetic Solutions | Magnetic Filtration
PATENTED DESIGN Filtramag+
Quick release swing clamps
Easy access for gloved hand
Patented high intensity magnetic rods & flow circuit
Restricted hinged lid - prevents over travel
Optional mesh strainer - removes non-magnetic debris (FM 2.0+ only)
Flanged connections (Hose tail adapters available)
Parallel inlet and outlet.
Integral base can be bolted to floor
Robust high performance magnetic filter with Dual Flow Technology to maximise collection capability. Easy installation with operation up to 20 bar.
Special applications
Ideal for use in a harsh chemical environments. Effective with carbide and cast iron applications.
For processes with high levels of contamination, high fluid flow rates, high viscosity fluids or that operate continuously, multiple Filtramag + filters can be installed in parallel using a manifold. Each Filtramag + can be isolated, using a manual valve and cleaned without stopping the process.
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Magnetic Filtration | Innovative Magnetic Solutions
How Filtramag+ works
Secondary filtration chamber
Primary filtration takes place
Secondary filtration takes place
Outlet
(Fig 3)
(Fig 1)
(Fig 2)
Fluid then passes through an optional mesh screen which removes non-magnetic debris. The patented magnetic circuit design ensures that the filter can never block even in high contamination applications. The magnetic cores can be removed easily by hand and cleaned with the tool supplied. As an option a spare magnetic cartridge can be supplied to ensure production continuity.
With a unique “Dual Flow Technology TM ” design (Fig 1) Filtramag + is the most efficient filter of its type available. The dual flow design ensures that fluid is exposed to the high intensity magnets for the maximum time, thus ensuring almost 100% of ferrous contamination is removed on the first pass. Fluid enters through the inlet and flows up through the primary filtration chamber, (Fig 2) it then flows down through the secondary filtration chamber (Fig 3).
Technical Data
E
A
C
FM2.0+
D
B
FM1.5+
Max. flow rate
Max. operating
Dimensions mm
Magnetic Strength
Product number
pressure Connection
A
B
C
D
E
PN16 flange
litres/min
bar
gauss
FM1.5 +
250
20
1 1 /
2 "
395
255
100
180
80.5
4,000
FM2.0 +
500
20
2"
442
330
100
250
80.5
4,000
FM1.5+/11K
250
20
1 1 /
2 “
395
255
100
180
80.5
11,000
FM2.0+/11K
500
20
2”
442
330
100
250
80.5
11,000
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Innovative Magnetic Solutions | Magnetic Filtration
Filtramag+ Mobile
Hose storage compartment
Integral Filtramag+ high intensity, dual flow filter
Outlet
On-board pump
Waste collection compartments
Hose storage compartment
Robust heavy-duty wheels
Spare magnetic cartridge - ensures continued use
An off-line filtration system for cleaning oils and coolants. This ‘Plug & Play’ unit offers efficient sub-micron filtration & can be moved easily from machine to machine.
Typical applications
Benefits
• Ferrous machining processes • Tank draining • Tank cleaning • Overnight fluid cleaning • Additional filtration • Incoming fluid inspection • Carbide applications
• Simple, “Quick-Connect” installation • High peformance, sub-micron filtration • Cleaner, longer lasting fluids • Cost savings in disposable filter usage • Improved surface finish and accuracy • Reduced waste disposable and oil wastage
Waste collection & recycling
Spare magnetic core included
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Magnetic Filtration | Innovative Magnetic Solutions
Construction
Technical Data
600mm Hoses: 3m long inlet and outlet hoses included, made from oil resistant PVC material, supplied with Cam lock connections. Magnet material: Rare Earth Neodymium Iron Boron (NdFeB) Magnet grade: N35 (standard), N45 (optional) Filter housing: 304 grade stainless steel (powder coated) Unit body: Mild steel (painted) Pump: Self priming AM 40-110B, single phase, 230V, 50HZ Power: 13 amp, 3 pin socket (other options available)
943mm
666.50mm
188.50mm
188.50mm
600mm
750mm
Performance Flow rate: 250 litres per minute | Magnetic performance: 4,000 Gauss (standard), 11,000 Gauss (optional) Contamination collection capacity: 3kgs | Operating temperature: 5˚C to 60˚C | Maximum suction height: 12.9m
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Innovative Magnetic Solutions | Magnetic Filtration
Autofiltrex
Reclaim Discharge
Inlet
Waste reclaim unit
3 way valve
High performance magnetic rods
Purge fluid outlet
All stainless construction
*Waste reclaim unit
Outlet
Pneumatic Cylinder
The latest generation in cost-effective fluid filtration. Fully automated operating & cleaning. Provides huge cost savings in fluids & filter consumables.
Benefits
Typical applications
• Cleaner fluid delivery to the machine • Reduced expenditure on filter media • Fully automated cleaning • Reduced waste disposal • Increased fluid lifespan • Improved surface finish and accuracy • 24/7 uninterrupted filtration
Autofiltrex is ideal for most ferrous machining applications such as grinding, honing, lapping, forming and quenching processes. It can be also utilised in wash station applications.
CO 2 e
g
P
o
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Magnetic Filtration | Innovative Magnetic Solutions
How Autofiltrex works
Autofiltrex works in-line, taking dirty fluid from the holding tank and delivering clean polished fluid to the tool/workpiece contact point. As fluid flows through the Autofiltrex cylinder, high intensity magnetic circuits extract ferrous contamination particles. When the magnets reach saturation point, a timed automated purging process lifts the magnetic cores from the housing thereby releasing contamination. This is simultaneously diverted via a 3-way valve to the reclaim unit (or when using AF1 to a purge or holding tank). The unit can be set to purge at timed intervals or be manually executed.
* AF1 unit is not supplied with a reclaim unit.
AF5
AF1
Technical Data
AF3
AF5
C
E
A B
F
D
Number of magnetic rods
Product number Flow rate
Magnetic Strength Connections
Contamination Capacity
Dimensions mm
Weight
A
B C D
E
F
gauss 9,000 9,000
mm
kgs
kg 30
ltrs/min.
AF1
60
1 3
19 31
1 3
N/A N/A 1504 250 N/A 210 872 852 1701 717 698 300
AF3-RC AF5-RC
150
122
200
5
9,000
38
5
145
872 852 1701 747 747 300
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Innovative Magnetic Solutions | Magnetic Filtration
PATENTED DESIGN Automag Skid
Automag magnetic filter 2-stage filter removes contamination down to sub-micron
size. Automated cleaning process
Purge valve automatically switched during the 'purge' process to send purged fluid and contamination to the purge tank
Purge tank holds purged fluid and
contamination before it is fed to the magnetic reclaim system
Magnetic reclaim separates contamination from the 'purge fluid', feeds clean fluid back into the system. Contamination is removed as semi-dry cake which can then be recycled
Height adjustable legs
Self-contained, free standing magnetic filtration system. Providing uninterrupted 24/7 filtration. Can be used in-line or with optional integral pump, off-line.
How Automag works
The purge tank then feeds the contaminated fluid to the magnetic reclaim whch removes the contamination, putting clean fluid back into circulation. The contamination is extracted in a form ready for disposal or recycling.
An Automag magnetic filter removes magnetic and para-magnetic contamination and holds it until it is released during the automated ‘purge’ process. Then, the filter’s output is briefly diverted so that fluid carries the contamination to the purge tank.
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Magnetic Filtration | Innovative Magnetic Solutions
Contamination is attracted to the tube of the cores. Cleaned fluid is re-circulated.
Compressed air lifts the cores from the tubes and the purge valve is opened. Contamination is released and washed away for collection.
Dual flow technology TM ensures that fluid is exposed to the high intensity magnets for the maximum time, thus ensuring almost 100% of ferrous contamination is removed on the first pass.
AM12 Skid
AM6 Skid
AM6 Skid Model
Pump PLC Purge Valves
Reclaim Recovery
AM12 Skid Model
Pump PLC Purge Valves
Reclaim Recovery
AM6S1
AM12S1
Single AM6 Skid
Single AM12 Skid
✔ ✔ ✔
✔ ✔ ✔
AM6S1/P
AM12S1/P Single AM12 Skid
Single AM6 Skid
✔ ✔ ✔ ✔
✔ ✔ ✔ ✔
AM6S2
AM12S2
Double AM6 Skid
Double AM12 Skid
✔ ✔ ✔
✔ ✔ ✔
AM6S2/P
AM12S2/P Double AM12 Skid
Double AM6 Skid
✔ ✔ ✔ ✔
✔ ✔ ✔ ✔
Innovative Magnetic Solutions | Magnetic Filtration
On board PLC
Double Automag Skid
Double Automag Skid units are available for large flow rate/heavy contamination applications.
Technical Data
B
C
A
∅ D1
∅ D2
∅ D3
Model
Number of cores
Maximum flow rate
Contamination capacity
Max. operating pressure
Dimensions mm
Litres/min. m³/hour
kgs
bar
A
B
C
D1
D2
D3
Flanges
AM6 Skid Single
6
450
27
6
10
1300 1540 1290/2190 75 (3")
50 (2")
50 (2") PN16/ ANSI
AM6 Skid Double
12
900
54
12
10
1300 2272 1290/2190 75 (3")
50 (2")
50 (2") PN16/ ANSI
AM12 Skid Single
12
900
54
12
10
1469 1743 1490/2390 75 (3")
75 (3")
75 (3") PN16/ ANSI
AM12 Skid Double
24
1800
108
24
10
1469 2475 1490/2390 75 (3")
75 (3")
75 (3") PN16/ ANSI
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Magnetic Filtration | Innovative Magnetic Solutions
Special Designs - AM32
AM32 is available for wash system applications up to 4,000 litres per minute flow rate (contact us for details).
Case Study
Industry: Tool Manufacturing Process Type: Grinding hand hacksaw blades Location: Jiangmen, South China Eclipse Product Installed: AutoMag 6 Skid Machined Material: M2 Steel The Challenge As a brand new machine, the creep feed grinder was fitted with a paper filter roll. In addition to being expensive when replaced regularly, the paper filters become contaminated by metal swarf quickly. Staff at the manufacturing facility decided to add an extra level of filtration in the form of a magnetic filter to capture and remove ferrous particles from the coolant. The Solution Eclipse Magnetics provided an AutoMag Skid magnetic filtration system. The AM6 AutoMag filter unit boasts 6 magnetic cores, and a maximum flow rate of 450 litres per minute. With a contamination capacity of up to 7kg, the AM6 has a maximum operating pressure of up to 10 bar. The magnetic filter, therefore, would remove the contamination before it reaches the paper filter, preventing it from clogging up and needing to be replaced frequently. Results The AutoMag Skid removes magnetic and para- magnetic contamination, down to sub-micron size, from the coolant used in the creep feed grinding machine. Therefore, the magnetic filter helps extending the life of the paper filter significantly, in turn saving money and reducing waste.
Photo: The contamination is dry when it is reclaimed.
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Innovative Magnetic Solutions | Magnetic Filtration
Installation Options
Pre-Filtration Installation - With Bypass Protect: • High pressure pump • Media filter (bags, cartridges, beds, etc) • Machine tool: through spindle components, tooling, keep sump clean, reduce wearing of part (way covers), extend coolant/oil life with no loss of physical properties
Pre-Filtration Installation - Duplex Advantages: • Ease of cleaning • Duplex magnetic filter • Constant high efficiency filtration
High Pressure Coolant Module or Existing Media Filtration
High Pressure Coolant Module or Existing Media Filtration
Valves
Bypass: for cleaning
MM or FM+
MM or FM+ Duplex Arrangement
Machine Tool CNC Mill, Lathe, Center or Grinder
Machine Tool
Valves
CNC Mill, Lathe, Center or Grinder
Machine Tool Sump Pump
Machine Tool Transfer Pump
Kidney Loop Filtration 24/7 Uninterrupted Cleaning Protect: • Tooling • Keep sump clean • General system cleanliness • Extend coolant life (with no loss of physical properties)
Post Filtration Installation - With Bypass Coolant Polishing Protect:
• Machine tool: through spindle components, tooling, extend coolant/oil life with no loss of physical properties, keep sump clean,and reduce wearing of parts (linear bearings)
Bypass (for cleaning)
Central Coolant Filter Tank, Quench Tank
Machine Tool
MM or FM+
OR
Valves
CNC Mill, Lathe, Center or Grinder
High Pressure Coolant Module or Existing Media Filtration
Bypass
Machine Tool Pump or Independent Pump ie. Skid/ Cart
Machine Tool
CNC Mill, Lathe, Center or Grinder
Machine Tool Transfer Pump
Valves
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Magnetic Filtration | Innovative Magnetic Solutions
Application Data Selector
Percentage reduction required from stated maximum flow rate to obtain good filtration results
Fluid Type
Material Type
Material Loading
Part No Flow rates (ltrs/min.)
Coolant/ Wash solution
Thin oil
Medium oil
Thick oil
Mild steel
Hard steel
Cast iron Stainless steel
High speed steel
Tungsten carbide
Heavy Medium Light
Wear
Manual
Micromag
MM5
70
0
20
n/a
n/a
0
n/a
20
n/a
n/a
n/a
n/a
n/a
n/a
✔
MM10
100
0
20
n/a
n/a
0
30
20
n/a
n/a
n/a
n/a
n/a
✔ ✔
150
0
20
30
60
0
30
20
70
n/a
n/a
n/a
MM20
✔ ✔ ✔
Filtramag+
FM1.5 + 250
0
10
20
40
0
20
20
50
60
70
n/a
✔ ✔ ✔
FM2.0 + 500
0
10
20
40
0
20
20
50
60
70
✔ ✔ ✔ ✔
Automated
Autofiltrex
AF1
60
0
10
20
40
0
20
20
50
60
70
n/a
✔ ✔ ✔
AF3-RC
150
0
10
20
40
0
20
20
50
60
70
✔ ✔ ✔ ✔
AF5-RC
200
0
10
20
40
0
20
20
50
60
70
✔ ✔ ✔ ✔
Automag Skid
AM6S1
450
0
10
20
30
0
20
20
40
50
60
n/a
✔ ✔ ✔
AM12S1
900
0
10
20
30
0
20
20
40
50
60
n/a
✔ ✔ ✔
AM6S2
900
0
10
20
30
0
20
20
40
50
60
n/a
✔ ✔ ✔
AM12S2 1800
0
10
20
30
0
20
20
40
50
60
n/a
✔ ✔ ✔
AM32S1 2000
0
n/a
n/a
n/a
0
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
✔
Example:
Centipoise Thin oil Medium oil
500 ltrs/min × Medium oil (20%) = 400 ltrs/min. 400 ltrs/min × Cast iron (20%) = 320 ltrs/min. Suggested flow rate = 320 ltrs/min.
20–300 300–700
Filter Flow
FM2.0 +
500 ltrs/min.
Material
Cast iron
Thick oil
700+
Fluid
Medium oil
25
Innovative Magnetic Solutions | Magnetic Filtration
Other filtration products
Ultrafiltrex - Protecting Oil & Gas Pipelines
Ultrafiltrex combines high performance magnetics with optimum flow to capture virtually 100% of black powder contamination in pipelines. It offers time, money and environmental savings in comparison to traditional membrane or barrier filters such as cyclones, cones, baskets and cartridges, which are limited by collection capability and prone to blockage.
Benefits of Ultrafiltrex
• Sub-micron particle size filtration capability • No consumables required or on-going costs
• Reduces waste disposal costs and environmental impact • Protects pipelines and components from abrasive wear • Ensures a cleaner, higher performance end product • Minimises downtime and maintenance costs • Provides protection in upstream, downstream and midstream sectors
Benefits of Boilermag • Guaranteed protection from black iron oxide • Easy installation and maintenance • Maintains peak performance of systems • Improves energy efficiency • Extends system life • No running costs, minimal maintenance costs • 10 year warranty The Boilermag range of filters removes black iron oxide from heating and cooling systems, improving efficiency, reducing C02 emission and protecting boilers from the damage that black iron oxide can cause. Boilermag - Heating System Protection
Liquid Filter - Protecting Food Processing Lines
The Liquid Filter magnetic separator has been designed to operate in pressurised transfer lines to provide protection against ferrous and para-magnetic contamination. Benefits of Liquid Filter • Can be used in any line that processes liquids at all viscosity levels • Can be supplied to suit various processing volumes, pressures, temperatures and specifications • Suitable for chocolate, jam, syrup, sauce, paste and beverage processing lines
26
Magnetic Filtration | Innovative Magnetic Solutions
“ I don’t know why we waited so long to have the Automag Skid unit installed in our plant. With the dollar savings we have seen thus far, I would have to say it was definitely a home run! ” Rick Daubert Tooling Engineer & Tool Room Supervisor at Ridg-U-Rack
Other Products In addition to our filtration range, Eclipse Magnetics manufacture a wide range of high performance magnetic products for diverse applications.
Workholding systems
Magnetic aids for workshop & general engineering applications
Lifting and handling systems
Magnetic materials & assemblies
Foreign body removal - Separation & detection systems
Heating system filters
Eclipse Magnetics Worldwide
Europe Atlas Way Sheffield S4 7QQ England
Americas 442 Millen Road, Unit 9, Stoney Creek Ontario, L8E 6H2, Canada T 001 905-664-5585 F 001 905-664-7090 sales@eclipsetoolsinc.com
China No. 168 Chengjian Road Minhang District
Shanghai PR China T (0086) 21 6434 8600 *150 F (0086) 21 6434 6488 szhou@eclipsemagnetics.com
T 0044 (0)114 225 0600 F 0044 (0)114 225 0610 info@eclipsemagnetics.com
Representative:
www.eclipsemagnetics.com
Eclipse Magnetics Ltd Atlas Way, Sheffield, S4 7QQ, England T +44 (0)114 225 0600 F +44 (0)114 225 0610 info@eclipsemagnetics.com | www.eclipsemagnetics.com
While every effort has been made to ensure the accuracy of the information in this publication, please note that specifications may change without notice.
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