Client Overview

A leading diesel fuel injection pump manufacturer in Chennai required a robust and scalable solution for its grinding shop. The facility housed multiple CNC grinding machines operating with neat cutting oil under highly critical machining conditions. To optimize productivity and reduce operating costs, the manufacturer sought a Centralized Coolant Filtration System that could replace individual tanks while ensuring consistent coolant quality and energy efficiency.

Challenges Faced

• Limited Floor Space: Individual coolant tanks occupied valuable space in the temperature-controlled, air-conditioned shop, restricting the addition of new machines.
  
• Inconsistent Oil Clarity: Maintaining stable oil clarity across eight grinding machines proved challenging, negatively impacting accuracy and productivity.
  
• High Power Consumption: Running multiple pumps for standalone systems significantly increased energy usage.
  

Maintenance Burden: Consumables, spares and routine maintenance required substantial resources.

Solution by Lex Technoaid

Lex Technoaid designed and installed a PLC-based Centralized Coolant Filtration System for a line of grinding machines. The system functioned as a CNC Coolant Filtration System, tailored to support neat cutting oil applications with high precision requirements. 

Key features included:

• VFD-controlled pumps to reduce cumulative energy consumption.
  
• IoT-enabled monitoring for real-time system health feedback and alerts for abnormal conditions.
  
• HMI panel interface for continuous updates, accessible by operators from any connected machine.
  
• Outdoor installation, which freed up space in the air-conditioned shop floor for critical machines while relocating coolant systems outside.
  

By implementing this centralized solution, individual tanks were eliminated and the air-conditioned plant could accommodate more grinding machines.

Outcome for the Client

• Increased Capacity: From the original eight grinding machines, the shop floor could now accommodate additional machines in the temperature-controlled environment.
  
• Consistent Oil Clarity: Improved coolant quality enhanced machining accuracy and extended tool life.
  
• Significant Power Savings: VFD-controlled pumps reduced overall power consumption.
  
• Lower Maintenance Costs: Reduced consumables and spare parts requirements decrease operational expenses.
  
• Smart Monitoring: PLC and IoT-enabled systems ensured operators received immediate alerts on performance, maximizing uptime.
  
• Proven Scalability: Following initial success, the same solution was successfully replicated across multiple production lines to achieve greater efficiency.