construction of and specifications for production and operational … · 2021. 8. 13. · iso 5598...

Mercedes-Benz MBN 9666-7Company Standard Date published: 2015-11

Supersedes: DBL 9666-KS:2014-04

Total no. of pages (including annexes): 28

Person in charge: Benjamin Witzel

Email: [email protected]

Plant: 010 Dept.: PT/TIA

Date of translation: 2016-02 Phone: +49(0)711 1767714

NOTE: This translation is for information purposes only. The German version shall prevail above all others.

Copyright Daimler AG

Construction of and Specifications for Production and Operational Equipment, Machines,

Systems, Facilities, and Devices Part 7: Cooling Lubricant Equipment

Foreword MBN 9666-7 contains hydraulic specifications and requirements for the procurement and construction of production and operational equipment, machines, systems, facilities, tools, and devices. MBN 9666-7 can be supplemented by requirement specifications, material approval lists (MFL), and other Daimler standards and specification documents. Project release does not necessarily result in MBN release, but instead can be limited to individual projects, locations, or model series. MBN 9666 consists of the following parts under the general title "Construction of and Specifications for Production and Operational Equipment, Machines, Systems, Facilities, and Devices": - Part 1: General Requirements (formerly A) - Part 2: Mechanical Equipment (formerly M) - Part 3: Electrical Equipment (formerly E) - Part 4: Pneumatic Equipment (formerly P) - Part 5: Hydraulic Equipment (formerly H) - Part 6: Lubrication Equipment (formerly S) - Part 7: Cooling Lubricant Equipment (formerly KS) - Part 8: Cooling Equipment MBN 9666 can be referenced in its entirety by indicating the standard number "MBN 9666 (all parts)" without mentioning a part document, or a part document can be referenced individually, e.g. as "MBN 9666-7". Changes First edition This edition supersedes the previous edition of DBL 9666 dated 2014-04.

Observe approval of procurement sources

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Contents 1 Scope ............................................................................................................................................. 4 2 Normative references ..................................................................................................................... 4 3 Terms and definitions ..................................................................................................................... 6 4 General requirements .................................................................................................................... 7 5 System requirements ..................................................................................................................... 7 6 Cooling lubricant circuit .................................................................................................................. 8 6.1 Cooling lubricant circuit design ...................................................................................................... 8

Supply, pressure, and volumetric flow rate at the cutting location ................................................. 8 6.1.1 Cooling lubricant volume ................................................................................................................ 9 6.1.2

6.2 Design specifications ................................................................................................................... 10 6.3 (Cooling lubricant) tanks .............................................................................................................. 10

Pump-back tank ........................................................................................................................... 11 6.3.1 Filtration tank ................................................................................................................................ 11 6.3.2 Sedimentation tank ...................................................................................................................... 12 6.3.3 Discharge tank ............................................................................................................................. 12 6.3.4 Clean tank .................................................................................................................................... 13 6.3.5

6.4 Supply and return paths ............................................................................................................... 13 6.5 Cooling lubricant return and chip transportation .......................................................................... 14

Variant 1 - transportation and return via flutes/pipes ................................................................... 14 6.5.1 Variants 2 and 3 - transportation and return using a pump-back station ..................................... 14 6.5.2 Variant 4 - transportation and return via conveyor systems with coarse-chip separator ............. 14 6.5.3 Variant 5 - transportation and return with pneumatic conveyors ................................................. 15 6.5.4

6.6 Temperature control of cooling lubricants .................................................................................... 15 6.7 Monitoring equipment ................................................................................................................... 15

Monitoring the filling level ............................................................................................................. 16 6.7.16.8 Equipment for separating liquid and solid foreign matter from water-mixed cooling lubricants .. 16 6.9 Electrical components .................................................................................................................. 17 7 KSS supply ................................................................................................................................... 17 7.1 Pumps in general ......................................................................................................................... 17 7.2 Non-self-priming centrifugal pumps ............................................................................................. 17 7.3 Self-priming centrifugal pumps .................................................................................................... 17 7.4 Immersion pumps ......................................................................................................................... 17 7.5 Gear pumps ................................................................................................................................. 18 7.6 Helical spindle pumps .................................................................................................................. 18 7.7 Compressed air diaphragm pumps .............................................................................................. 18 7.8 Diaphragm piston pumps ............................................................................................................. 18 8 KSS control and regulation .......................................................................................................... 18 8.1 Directional control valves ............................................................................................................. 18

Operation types ............................................................................................................................ 18 8.1.1 Directional control valves up to a nominal width of 65 ................................................................. 18 8.1.2 Directional control valves up to a nominal width of 80 ................................................................. 18 8.1.3

8.2 Shutoff fittings .............................................................................................................................. 19 Ball valves .................................................................................................................................... 19 8.2.1 Shutoff flaps ................................................................................................................................. 19 8.2.2 Diaphragm valves ........................................................................................................................ 19 8.2.3

9 Filtration and conditioning of the KSS .......................................................................................... 19 10 KSS transfer ................................................................................................................................. 19 10.1 General requirements for lines and connections ......................................................................... 19 10.2 Tube and hose connectors........................................................................................................... 19 10.3 Pipe requirements ........................................................................................................................ 19

Steel piping .................................................................................................................................. 19 10.3.1 Stainless steel piping ................................................................................................................... 19 10.3.2

10.4 Pipe fittings and connections ....................................................................................................... 20 Cutting ring fittings ....................................................................................................................... 20 10.4.1 Deformation fittings ...................................................................................................................... 20 10.4.2

10.5 Line system brackets ................................................................................................................... 20 10.6 Hose assemblies and fittings ....................................................................................................... 20

Hoses as per DIN 20021, DIN EN 853, and DIN EN 856 ............................................................ 21 10.6.1 Hose fittings ................................................................................................................................. 21 10.6.2 Hoses with fabric sheaths ............................................................................................................ 21 10.6.3

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Requirements for hose assemblies .............................................................................................. 21 10.6.4 Installation .................................................................................................................................... 21 10.6.5 Protection against failure .............................................................................................................. 21 10.6.6

11 Monitoring, control, and switching units ....................................................................................... 22 11.1 Fill level switches ......................................................................................................................... 22 11.2 Temperature switch, electronic .................................................................................................... 22 11.3 Flow sensors ................................................................................................................................ 22

Electronic flow monitor with digital display ................................................................................... 22 11.3.1 Electronic volume sensors with digital display ............................................................................. 22 11.3.2

12 Other devices, rotary distributor/rotary feed through ................................................................... 22 13 Material selection and materials subjected to cooling lubricants ................................................. 23 13.1 Sealing materials .......................................................................................................................... 23 13.2 Materials for pipes, hoses, and fittings ......................................................................................... 23 13.3 Interaction of slideway materials, slideway oils/grease with KSS ................................................ 23 13.4 Coating materials for machines ................................................................................................... 24 13.5 Metallic materials ......................................................................................................................... 24 13.6 Adhesives ..................................................................................................................................... 24 14 Occupational safety and environmental protection equipment .................................................... 25 14.1 Technical measures for preventing skin contact .......................................................................... 25 14.2 Encapsulation of machine tools and production facilities, and extraction

and separation of cooling lubricant fluid aerosols and vapors ..................................................... 25 Design of the collecting facilities .................................................................................................. 25 14.2.1 Routing of extraction air ............................................................................................................... 26 14.2.2 Separation of aerosol contents and vapors ................................................................................. 26 14.2.3

14.3 Environmental protection systems (directives and regulations)................................................... 26 15 Maintenance, cleaning and care .................................................................................................. 27 15.1 Cooling lubrication documents ..................................................................................................... 27

Lubrication data sheet .................................................................................................................. 27 15.1.1 Cooling lubrication circuit diagram ............................................................................................... 28 15.1.2

15.2 List of equipment (component part list) ........................................................................................ 28

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1 Scope This document shall be applied for all production and operational equipment, machines, systems, facilities, and devices, as well as replacement and wear parts that are directly or indirectly procured for the manufacture of products within the Daimler Group. Particular attention was given to: • Safety • Uninterrupted system operation • Simple and economic maintenance • Long service life of the hydraulic system

2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any changes) applies.

DBL 6714 Negative List – Constituents of Process Materials

DBL 8585

General Requirements – Environmental Protection, Hazardous Substances, Dangerous Goods – Negative Substance List for the Selection of Materials

MBN 9666-2 Construction of and Specifications for Production and Operational Equipment, Machines, Systems, Facilities, and Devices, Part 2: Mechanical Equipment

MBN 9666-3 Construction of and Specifications for Production and Operational Equipment, Machines, Systems, Facilities, and Devices, Part 3: Electrical Equipment

MBN 9666-5 Construction of and Specifications for Production and Operational Equipment, Machines, Systems, Facilities, and Devices, Part 5: Hydraulic Equipment

MBN 9666-5, Supplementary Page 2

Hydraulic Hose Record List

DIN 2353 Non-Soldering Compression Fittings with Cutting Ring - Complete Fittings and Survey

DIN 3015-1 Fastening Clamps - Block Clamps - Part 1: Light Duty (L)

DIN 3015-2 Fastening Clamps - Block Clamps - Part 2: Heavy Duty (S)

DIN 3015-3 Fastening Clamps - Block Clamps - Part 3: Double Clamps

DIN 3861 Non-Soldering Compression Fittings - Compression Rings - Design

DIN 20021 Fluid Systems - Hoses with Layer - Completion for DIN EN 853 to DIN EN 857

DIN 20066 Hydraulic Fluid Power - Hose Assemblies - Dimensions, Requirements

DIN 24339 Hydraulic Fluid Power - Reservoirs Made of Steel, Nominal Sizes 63 to 1250 - Dimensions, Requirements, Testing

DIN 24557-2 Fluid Power; Air Breathers; Connecting Dimensions

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DIN EN 853 Rubber Hoses and Hose Assemblies - Wire Braid Reinforced Hydraulic Type

DIN EN 856 Rubber Hoses and Hose Assemblies - Rubber-Covered Spiral Wire Reinforced Hydraulic Type - Specification

DIN EN 857 Rubber Hoses and Hose Assemblies - Wire Braid Reinforced Compact Type for Hydraulic Applications - Specification

DIN EN 10216-5 Seamless Steel Tubes for Pressure Purposes – Technical Delivery Conditions – Part 5: Stainless Steel Tubes

DIN EN 10297-1 Seamless Circular Steel Tubes for Mechanical and General Engineering Purposes - Technical Delivery Conditions - Part 1: Non-Alloy and Alloy Steel Tubes

DIN EN 10305-1 Steel Tubes for Precision Applications - Technical Delivery Conditions - Part 1: Seamless Cold Drawn Tubes

DIN ISO 12151-2

Connections for Hydraulic Fluid Power and General Use - Hose Fittings - Part 2: Hose Fittings with ISO 8434-1 and ISO 8434-4 24° Cone Connector Ends with O-Rings

DIN EN ISO 4413 Hydraulic Fluid Power - General Rules and Safety Requirements for Systems and Their Components

DIN EN ISO 8434-1 Metallic Tube Connections for Fluid Power and General Use – Part 1: 24 Degree Cone Connectors

DIN EN ISO 9717 Metallic and other Inorganic Coatings - Phosphate Conversion Coating of Metals

DIN EN ISO 12944-4 Paints and Varnishes - Corrosion Protection of Steel Structures by Protective Paint Systems - Part 4: Types of Surface and Surface Preparation

DIN VDE 0100-410 Low-Voltage Electrical Installations - Part 4-41: Protection for Safety - Protection Against Electric Shock

ISO 1219-1 Fluid Power Systems and Components - Graphical Symbols and Circuit Diagrams - Part 1: Graphical Symbols for Conventional Use and Data-Processing Applications

ISO 1219-2 Fluid Power Systems and Components - Graphical Symbols and Circuit Diagrams - Part 2: Circuit Diagrams

ISO 5598 Fluid Power Systems and Components - Vocabulary

VDI 2262 SHEET 3 Workplace Air - Reduction of Exposure to Air Pollutants - Legal Principles, Terms and Definitions, Basic Organisational Measures for Industrial Safety and Environmental Protection

VDI 2262 Part 4 Workplace Air - Reduction of Exposure to Air Pollutants - Recording Air Pollutants

VDI 3035 Design of Machine Tools, Production Lines and Peripheral Equipment for the Use of Metalworking Fluids

VDI 3397 SHEET 1 Cooling Lubricants for Abrasive and Reforming Production Methods

VDI 3397 SHEET 2 Workplace Air - Reduction of Exposure to Air Pollutants - Processing and Organisation Measures

VDI 3397 SHEET 3 Disposal of Cooling Lubricants

VDI 3802 SHEET 1 Air Conditioning Systems for Factories

VDI 3802 SHEET 2 Air Conditioning Systems for Factories - Extraction of Airborne Pollutants on Abrasive Machine Tools

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3 Terms and definitions The terms and definitions as per ISO 5598 and the following terms and definitions shall apply to this supply specification:

Drive A component part that converts the energy of the pressure medium to mechanical energy (e.g. motor, cylinder).

Acceptance Process by which a client formally accepts a system

Component Individual unit (e.g. cylinder, motor, valve or filter, but excluding line systems) consisting of one or more parts designed as a functional component of fluid power systems

Control mechanism Device that provides an input signal to a component (e.g. lever, solenoid)

Emergency control unit Control system that brings a system to a safe condition

Function plate

Contains information describing either the function of a control mechanism (e.g. on/off, forward/reverse, left/right, up/down) or the function performed in the system (e.g. clamping, lifting, feeding)

Control device Equipment that supplies control systems with an input signal (e.g. cam, electrical switch)

Line system Any combination of adapters, couplings, or connectors with lines, hoses, or tubes which allows hydraulic fluid flow between components

Client Contracting party who stipulates the requirements of a machine, equipment, systems, or components and assesses whether the product satisfies these requirements

Contractor Contracting party who is obliged to provide the product(s) in accordance with the client's requirements

System Arrangement of interconnected components which transmits and controls fluid power energy

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Additional terms and definitions BQF Approval of procurement sources DBL Daimler-Benz Supply Specification DIN German Industrial Standard (Deutsche Industrie Norm) EN European Standard EP Epoxy resin FKM Fluorocarbon rubber GGA Hazardous goods and materials HBV system System to produce, treat, and use substances hazardous to water KSS Cooling lubricant MBN Mercedes-Benz Standard (Mercedes-Benz-Norm) PTFE Polytetrafluoroethylene PUR Polyurethane resin

4 General requirements For safety requirements, homologation (in particular, exhaust emissions), and quality, the existing statutory requirements and laws shall be complied with. In addition, the relevant requirements of the Daimler Group apply. All materials, procedures, processes, components, and systems shall conform to the current statutory requirements regarding regulated substances and recyclability. Cooling lubricant components that are not described in this MBN 9666-7 shall only be approved and thus authorized for use by employing the process described in MBN 9666-2. Within a project, approval is granted in collaboration with the corporate-level working group (AK). The provisions of DBL 8585 and DBL 6714 shall be observed.

5 System requirements The following system requirements are intended to guarantee the operational safety of machine tools and production systems, increase the efficiency when using cooling lubricants (also referred to as metalworking fluids or KSS) and simultaneously restrict the repair costs to a minimum. This Standard describes the design characteristics of machine tools and systems that are required when using cooling lubricants as part of metal cutting and reshaping. The discussion also takes into account mandatory legal requirements, e.g. legislation on the efficient use of water, on the basis of the list of requirements for HBV systems (systems to produce, treat, and use substances hazardous to water) and the regulations of commercial trade associations, as well as the Technical Rules for Hazardous Substances. VDI 3397 SHEET 1 to SHEET 3 contain detailed information about cooling lubricants for cutting and reshaping production methods. As a rule, the discussion shall be primarily applied to machine tools with independent cooling lubricant systems. However, it is also valid for machine tools and production systems with central lubrication. The machine shall be specially designed if minimum-quantity lubrication is applied.

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6 Cooling lubricant circuit Cooling lubricant circulation systems on machine tools and production systems are integrated into a functional circuit consisting of certain system equipment and components that take into account the production requirements with regard to cooling lubricants, cutting process, material, chip shape, chip quantity, heat absorption, and introduction of foreign substances.

6.1 Cooling lubricant circuit design In supplying cooling lubricant to machine tools and production systems, a distinction is drawn between individual, group, and centralized lubrication circulation systems. In compliance with occupational safety and environmental protection legislation (see MBN 9666-7, Section 14), the design of the corresponding KSS circuit systems shall be based on the processing method and the primary tasks, such as the following: • Cooling • Lubricating • Flushing • Conveying of chips (VDI 3397 SHEET 1) Figure 1 shows the principal cooling lubricant circuit system components: • Cooling lubricant return and chip transporting equipment

(e.g. flutes, conveyors, pipes, pump-back stations) • Care section (e.g. tanks, pumps, filters, temperature control equipment, monitoring devices) • Cooling lubricant supply (e.g. pumps, pipes, measuring and control equipment, mixing devices) • Chip treatment (e.g. conveyors, chip breakers, centrifuges, chip presses, chip containers)

Figure 1: Cooling lubricant circuit

Supply, pressure, and volumetric flow rate at the cutting location 6.1.1

It is essential that the cooling lubricant is delivered directly and continuously to the tool cutting location to reduce the friction on the cutting tools, ensure chip transporting, and ensure optimum heat dissipation. For this reason, the supply type (nozzle design and positioning) has a special importance in addition to the quantity supplied per time unit.

Chip treatment

Care stage

KSS supply KSS return

Machine tool

Production system

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The use of several nozzles is practical when grinding, turning, milling, drilling, etc. This is the only way to ensure that the tasks of "cooling, lubricating, flushing" ideally meet the different requirements for cooling lubricant supply. Branch lines in which the cooling lubricant is not continuously circulated shall be avoided. The KSS flow shall be supplied to the cutting location immediately before, during, and after the tool intervention to supply the secondary cooling lubricant consumers during the workpiece conveying cycle and avoid unnecessary filter equipment loads. Regulating devices shall be used to ensure that the cooling lubricant volumetric flow rates can be adjusted reproducibly at the individual points of use. With metal cutting processes, the cooling lubricant can be delivered within or outside the tool. In both cases, design solutions shall be applied which prevent rebounding cooling lubricant from penetrating into the bearings of the working spindles and guides (baffle disk, labyrinth seals, etc., air curtain, overpressure in the bearing chamber). Pressure and volumetric flow rate shall be configured so that the chip spaces remain clear to maintain the chip formation process.

Cooling lubricant volume 6.1.2

The design and dimensions of the system tanks, as well as the specification of the required cooling lubricant volume, are of special importance during the cooling lubricant circuit design. The following criteria shall be taken into account: • Recirculation number Uz

(theoretical number of times the fluid - operating volume - changes per hour) • Residence time X

(theoretical dwell time of the cooling lubricant with respect to the net contents of the tank) In practical application, the simplified determination of the cooling lubricant volumetric flow rate as per Table 1 using the so-called recirculation number Uz, for which empirical values are available depending on the particular application case, has proven useful.

Type of cooling lubricant

Water-mixed cooling lubricant Non-water-miscible cooling lubricant

Residence time X (min) 10 to 6 20 to 10

Recirculation no. Uz (1/h) 6 to 10 3 to 6

Table 1: Cooling lubricant requirement

The operating volume Vb in m3 is determined using the recirculation number Uz and the volumetric flow rate V̇e. The operating volume Vb equals the minimum volume Vm plus the travel volume Vr. Operating volume Vb in m3 = V̇e : Uz V̇e Effective volumetric flow rate (m3/h) Uz Recirculation number (1/h) X Residence time (in special cases < 6 min), e.g. for pressure > 5 bar or 5 x 105 Pa) in minutes. There is the following relationship between the recirculation number Uz and the residence time X: X = 60lUz.

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The more often the fluid circulates, the shorter the residence time X in the tank and thus the time available to separate out foreign matter and air and also for heat dissipation. Chiller systems may be required to guarantee the required heat output. A gap Vl to absorb any foam shall be provided. Higher recirculation numbers are permitted, as agreed with the responsible specialist department, for individually supplied machines to implement a tank size that complies more readily with the requirements for recurring tests as per VAwS. A recirculation number of 15 for water-mixed cooling lubricants or 9 for non-water-miscible cooling lubricants shall not be exceeded under any circumstances.

6.2 Design specifications The manufacturer or supplier of the machine shall receive data about the type of KSS used and the processed material during the design phase of the machine tool. The use of cooling lubricants within a circuit shall require special attention to the specifications defined in VDI 3397 SHEET 1 to SHEET 3 regarding their use and their maintenance options, as well as the tank design for the cooling lubricant as described in the following sections. In the case of minimum-quantity lubrication, deviating design criteria as per VDI 3802 SHEET 1 and SHEET 2 shall apply. The machine bed shall, among other factors, be designed so that the chips are discharged from the machine without the need for additional KSS quantities. Furthermore, the machine tool hydraulics shall be designed so that hydraulic fluid leaks are prevented or fluid cannot enter the cooling lubricant circuit.

6.3 (Cooling lubricant) tanks Clean and dirty tanks shall be capable of holding the entire KSS in circulation (primary level control). The filtration unit and fluid care equipment shall be connected to them. The following criteria shall be taken into account when designing the cooling lubricant tanks: • Radiation or dissipation of the absorbed heat

(large surface area, long residence time, possibly cooling) • Separation of the entrained air and prevention of foam formation

(large surface area, long residence time, wide inlets arranged with shallow gradients or tangentially) • Reliable separation of the chips and grinding sludge in the waste tanks using suitable measures

(e.g. flushing devices to discharge floating grinding sludge) • Base area and machine outlet (slope from machine to tank) • Ease of maintenance (accessibility, discharge of residue, slope towards the draining point,

fill level monitoring, sampling) • The opening of the tank shall be designed so that all areas can be cleaned. • The installation location of the tank shall be coordinated with the Daimler specialist department. • It is not permitted to install tanks in pits. • The tanks shall not have internal coating, external paint coat (see MBN 9666-7, Section 13) • Transportation (e.g. adequately dimensioned tie-down hooks) • Refilling cooling lubricant shall also be possible when the machine is running

(see MBN 9666-7, Section 6.7)

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Pump-back tank 6.3.1

In systems supplied with lubricant individually, in groups, or centrally, the cooling lubricant collected at individual machines shall be fed to the supply system using a pump-back tank as per Figure 2 if gravity-based discharge is not possible due to insufficient incline. The tanks shall be designed so that deposits are avoided (e.g. round tanks with a pointed base). Sedimentation in the return system and foam in the filtration tank shall be avoided (e.g. by level-based pump control and as large a surface as possible to increase the air releasing properties).

Figure 2: Arrangement for pump-back tanks

Filtration tank 6.3.2

The filtration tank as per Figure 3 has an additional filter system in addition to the chip conveyor described in the section on the discharge tank. The filter and fineness grade shall be adapted to the requirements. Automatic low-waste filters shall be used. An additional buffer tank can be connected to increase the volume.

Figure 3: Filtration tank

Machine tool

1 Filter 2 Chip conveyor

Top view

Clean tank

Filtration tank

Machine tool

To the supply system

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Sedimentation tank 6.3.3

In this case, the cooling lubricant is cleaned by sedimentation (settling as a result of gravity), Figure 4.

Figure 4: Sedimentation tank

The contamination discharge is carried out using suitable conveyor systems. Depending on the processing method and size of the chips, a combination with other KSS cleaning methods shall be used. The use of sedimentation tanks only is not sufficient, in particular for fine machining processes such as grinding.

Discharge tank 6.3.4

The discharge tank as per Figure 5 consists of a tank with chip conveyor. The generated chips and larger solids shall be removed continuously using suitable conveyors, e.g. scrapers. An additional buffer tank shall be connected if the volume of the tank on its own is not sufficient for the supply.

Figure 5: Discharge tank

Machine tool

a) Scraper conveyor

Top view

Buffer tank

Discharge tank

Machine tool

Conveyor

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Clean tank 6.3.5

The clean tank as per Figure 6 serves to collect the cleaned cooling lubricant. It is not free from solids because the complete separation of solids would be cost prohibitive. Deposits of remaining particles shall be prevented by pointed or inclined bases and extraction at the lowest point.

Figure 6: Clean tank

6.4 Supply and return paths When designing the supply and return paths, including the piping and hoses, attention shall be paid to the following points: • All pipes and hoses shall feature a sufficient clear diameter to keep friction loss to a minimum

and prevent unnecessary heating of the cooling lubricant. Extremely narrow cross-sections shall be avoided due to impermissible cavitation and the associated noise (flow rate for suction lines approximately 1,0 to 1,5 m/s; for pressure lines approximately 2,0 to 2,5 m/s).

• The intake aperture shall be approximately 2,5 d (d = clear diameter of the suction line) from the minimum level of the fluid to prevent an intake of air. An inclined installation of the intake pipe is recommended.

• Horizontal areas or recesses in the machine bed and return lines shall be prevented. It shall be possible to drain the entire system, and with the exception of the tank there shall be no additional cavities where the cooling lubricant can be stagnant and contamination may occur.

• The materials used for seals, lines, paint, etc. shall be resistant to the effects of intended cooling lubricants (see MBN 9666-7, Section 13).

• Hydraulic, lubrication, and cooling lubricant circuits shall be designed so that liquid media do not mix with each other (see MBN 9666-7, Section 13).

• Venting, pumping effects, and draining shall be taken into account when installing the pipes. Suction lines shall be installed with an upward gradient to the pump.

• If the cooling lubricant supply line is supplied by a manifold, the line shall be installed on the top or side of the manifold. A purge line shall be installed at the lowest point of the distributor pipe end to be able to flush out dirt deposits.

• In central lubrication systems the shutoff devices shall be installed in the distribution paths to prevent contamination of the shutoff devices.

Machine tool

a) Inclined base b) Pointed base

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6.5 Cooling lubricant return and chip transportation As a rule, the chips developing during machining enter the cooling lubricant and are conveyed with it to filter/cleaning systems or separately to chip processing. Depending on the structural characteristics of the machine and the selected cooling lubricant system, different concepts/methods for returning KSS and transporting chips can be used. Large bending radii shall be used for piping (depending on MBN 9666-7, Section 6.4).

Variant 1 - transportation and return via flutes/pipes 6.5.1

Short and long chips from the machine tool enter the cleaning system with the KSS. A flushing system with flushing nozzles shall support transportation, if required. Flutes shall always be covered tightly.

Figure 7: Different variants [1] to [5] and principles of cooling lubricant return/cleaning

and chip transportation

Variants 2 and 3 - transportation and return using a pump-back station 6.5.2

Short chips from the machine tool that are suitable for pumping travel via pump-back stations to the return lines. Longer chips can be reduced to dimensions suitable for pumping using chip breakers or separated at the machine and disposed of. The return pumps convey the KSS/chip mixture to the cleaning unit using a closed piping system

Variant 4 - transportation and return via conveyor systems with coarse-chip separator 6.5.3

The KSS with short and long chips travels from the machine tool to a conveying system (scraper conveyor, push-bar conveyor, etc.). Here the coarse and long chips are removed using a slotted screen section and supplied to chip processing. The KSS with the small dirt particles and short chips is carried via piping to the cleaning equipment.

Conveyors

Machine tools

Chip separation unit

Large chips Separator

Return pump

Chip breaker

Conveyor systems

with large chip

separator

Conveyors

Cleaning equipment (see also VDI 3397, Sheet 2)

Chip treatment

KSS circuit

Chips

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Variant 5 - transportation and return with pneumatic conveyors 6.5.4

Short and long chips are removed from the KSS at the machines by presettling tanks. The KSS with the remaining small dirt particles reaches the cleaning unit via return pumps and pipes. The separated long chips are crushed by chip breakers and together with the short chips removed by suction at the machine tools via a pneumatic conveyor system and delivered to the chip processing unit.

6.6 Temperature control of cooling lubricants If the workpiece is subject to strict precision requirements, the cooling lubricant in the circulation system may have to be temperature controlled, i.e. it can be cooled (VDI 3397 SHEET 1) or heated. The ambient temperature shall be the reference variable for temperature control. Additional process- and machine-related temperatures shall be available for selection (VDI 3397 SHEET 2). If the ambient temperature is subject to short-term fluctuations, the temperature of a component with high mass such as the machine bed or column should be used as the reference variable. In machines with large evaporation surfaces, evaporation heat loss shall be added to the required heat output of the temperature control units. When refilling using water from the public supply network, an often very marked temperature drop of the cooling lubricant can be observed. A heat output of 0,8 W/cm2 shall not be exceeded with non-water-miscible cooling lubricants. An output of up to 6 W/cm2 shall be complied with for emulsions. An adequate flow rate is important for preventing deposits and cracking. The surface temperature of 100 °C shall not be exceeded when using a heat exchanger. Immersion heaters shall be protected by safety thermostats or dry protection. Lines with temperature-controlled media shall be insulated to increase the efficiency. With temperature controlled cooling lubricants, the return of the cooling lubricant to the tank and the supply flow from the tank to the cutting location shall be coordinated with or designed for the heat flow.

6.7 Monitoring equipment Suitable devices on the machine tools shall monitor the cooling lubricant pressure and/or flow rate. The device type (pressure and/or flow) shall be coordinated with the Daimler specialist department. If required, the cooling lubricant temperature shall additionally be monitored. The state of wear of the pumps influences the pressure and the volumetric flow rate. As both factors are important for process assurance, comparative measurements with the new pump status shall be carried out at regular intervals.

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Monitoring the filling level 6.7.1

It shall be possible to read the fill level of each cooling lubricant tank, e.g. using a filling aperture, inspection glass, or fill level gauge. The fill levels shall be monitored and controlled by electrical devices. The maximum fill levels when the machine is idle and when it is running, as well as the minimum fill level (while the machine is running), shall be permanently marked on each tank; see Figure 8.

Figure 8: Fill level monitoring of cooling lubricant tanks

Vtotal = Vm + Vr + Vn + Vl Vtotal Cooling lubricant tank capacity Vm Minimum cooling lubricant volume in operating mode Vn Refill volume (entrainment + evaporation) Vr Travel volume (filling capacity of the supply and return systems) Vl Gap above the maximum fill level (e.g. with foam formation approximately 25 % of the overall height) The tank filling shall be performed only using line connections fixed in place and non-return valves, pipe separators, and an overfill protection device. Exceptions include: • Individually used, stationary tanks with a maximum capacity of 1000 l • Tanks refilled from smaller, mobile transport tanks, provided that the fill level of the tank is clearly

visible by sight in the area of the permissible fill level during the filling process, so that the refilling process can be interrupted prior to reaching the permitted fill level.

6.8 Equipment for separating liquid and solid foreign matter from water-mixed cooling lubricants

If foreign oil can be expected in the KSS tanks, there shall be a system (e.g. ring chamber oil separator, separator, or skimmer) to remove the foreign oil as per VDI 3397, SHEET 2. If systems to remove foreign oil are used, a calming zone shall be provided in the KSS system (except the ring chamber oil separator). • It shall be ensured with a ring chamber oil separator that it is connected to the presetting tank

to reduce contamination. Removing foreign oil from the KSS using ring chamber oil separators represents gentle KSS treatment. The deoiling can be performed continuously in the main or partial flow.

• Excessive separation of KSS constituents by the separator shall be prevented. To this end,

coarsely dispersed KSS shall be handled with particular care. • Skimmers shall feature adequately large, low-turbulence surfaces. The skimmer is only capable

of removing floating oils and cream layers.

Alarm!

Refilling level (during operation)

Max. filling (at standstill)

Alarm! Dry run protection

Refilling message (start) (Minimum fill level in operation)

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• The statements concerning the skimmer do not apply to coalescence oil separators. The top liquid layer, i.e. also the area where the foreign oil concentrates, is evacuated by a floater and the separation process is carried out separately. The oil separator works in the partial flow.

The separation of solid foreign matter requires special cleaning systems such as centrifugal separators, magnetic separators and/or filtration systems.

6.9 Electrical components Electrical components shall be protected from contact with KSS. The integrity and resistance to KSS and KSS vapors/aerosols, and the resistance to chips, shall be assured as per DIN VDE 0100-410.

7 KSS supply

7.1 Pumps in general There are different pump types for the different tasks. Selection criteria shall include the proportion of solids in the cooling lubricant, viscosity, the desired volumetric flow rate of the cooling lubricant at the cutting location, and the required pressure. The pumps used here are grouped by their operating principle and their design. • Smaller units are designed as block pumps. In this case, the pump and motor shafts are produced

from a single piece, thus creating a compact design. Pumps are used as immersion pumps in smaller systems and individual machines (primarily in chip conveyors);otherwise they are arranged horizontally or vertically (cooling lubricant for supply and disposal).

• Non-chokable pumps or channel-type impeller pumps shall be used to convey contaminated cooling

lubricant, in part for conveying the chips hydraulically. These pumps shall be designed as immersion pumps without shaft seal. Multi-stage variants shall be supported on the shaft in the pump body using plain bearings made of carbide.

Water-sealed systems in pumps shall be designed in a closed circuit.

7.2 Non-self-priming centrifugal pumps The use of non-self-priming centrifugal pumps shall be coordinated with the project management and the responsible technical specialist department at Daimler.

7.3 Self-priming centrifugal pumps The use of self-priming centrifugal pumps shall be coordinated with the project management and the responsible technical specialist department at Daimler.

7.4 Immersion pumps The use of immersion pumps shall be coordinated with the project management and the responsible technical specialist department at Daimler.

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7.5 Gear pumps The use of gear pumps shall be coordinated with the project management and the responsible technical specialist department at Daimler.

7.6 Helical spindle pumps The design of Allweiler pumps is permitted only with a pressure regulating valve as per BQF 9666-7. The use of helical spindle pumps shall be coordinated with the project management and the responsible technical specialist department at Daimler.

7.7 Compressed air diaphragm pumps The use of compressed air diaphragm pumps shall be coordinated with the project management and the responsible technical specialist department at Daimler.

7.8 Diaphragm piston pumps Use for abrasive media for grinding water pressure increase The use of diaphragm piston pumps shall be coordinated with the project management and the responsible technical specialist department at Daimler.

8 KSS control and regulation

8.1 Directional control valves

Operation types 8.1.1

• Electrical Protected from unintentional activation in the event of an installed manual emergency activation. Plug-in device for each magnet as per MBN 9666-3 Connection diagram as per MBN 9666-3 Line socket with LED as per sample plan in MBN 9666-3 • Hydraulic • Pneumatic • Mechanical The design shall employ position interrogation. Deviations shall be agreed with the specialist department.

Directional control valves up to a nominal width of 65 8.1.2

The use of directional control valves up to a nominal width of 65 shall be coordinated with the project management and the responsible technical specialist department at Daimler.

Directional control valves up to a nominal width of 80 8.1.3

The use of directional control valves up to a nominal width of 80 shall be coordinated with the project management and the responsible technical specialist department at Daimler.

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8.2 Shutoff fittings

Ball valves 8.2.1

The use of ball valves shall be coordinated with the project management and the responsible technical specialist department at Daimler.

Shutoff flaps 8.2.2

The use of shutoff flaps shall be coordinated with the project management and the responsible technical specialist department at Daimler.

Diaphragm valves 8.2.3

The use of diaphragm valves shall be coordinated with the project management and the responsible technical specialist department at Daimler.

9 Filtration and conditioning of the KSS Only filter equipment with filter materials that can be regenerated are permitted. The use of filter equipment shall be coordinated with the project management and the responsible technical specialist department at Daimler.

10 KSS transfer

10.1 General requirements for lines and connections Pipes, hoses, and hose fittings shall be made of materials that are resistant to the media used. Corresponding verification shall be submitted to the client on request prior to delivery.

10.2 Tube and hose connectors Mixed assemblies with different makes and materials are not permissible.

10.3 Pipe requirements

Steel piping 10.3.1

• Only seamless precision steel pipes as per DIN EN 10305-1 or DIN EN 10297-1 are permitted • Normalized, pre-heated blank, surface with galvanic corrosion protection

Stainless steel piping 10.3.2

• Only seamless precision steel piping as per DIN EN 10216-5 is permitted

(1.4571, X6CrNiMoTi17-12-2) or (1.4541, X6CrNiTi18-10)

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10.4 Pipe fittings and connections Soft seals shall be made of fluorocarbon rubber (FKM).

Cutting ring fittings 10.4.1

• Non-soldered pipe fittings with cutting ring and cutting ring fitting as per DIN 2353. • Metal pipe fittings with 24° cone as per DIN EN ISO 8434–1. • Pipe fittings with double-edge cutting ring and type B as per DIN 3861. • Flange connections with a nominal width of 50 or greater, design as per SAE

• The use of sealing systems featuring soft ring seals shall be coordinated with project management

and the responsible, technical Daimler specialist department.

Deformation fittings 10.4.2

Pipe connections with soft seal, stud, and union nut in accordance with DIN 2353 and ISO EN ISO 8434-1.

10.5 Line system brackets Attachment clamps shall be designed as blocks as per DIN 3015-1 to -3 If necessary, piping shall be securely supported both at its ends and at intervals along its length by appropriately designed brackets. All manufacturer installation specifications concerning space requirements, minimum line separations, and pipe clamp intervals shall be observed depending on the piping and mounting systems. The requirements of DIN EN ISO 4413 shall be fulfilled as a minimum. The installation of mounting clamps shall be done in accordance with MBN 9666-5.

10.6 Hose assemblies and fittings As a rule, the piping shall be designed as fixed piping. Hose assemblies shall be restricted to mobile connections. Hose assemblies are permitted only in the following cases: • For movable units • For production-related unit changes • In order to reduce the transmission of mechanical and hydraulic vibrations and/or noise The hose length shall be restricted to the necessary minimum dimensions. Hose assemblies shall be documented in the hose record list as per MBN 9666-5, Supplementary Page 2 Mixed installations with different makes are not permitted.

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Hoses as per DIN 20021, DIN EN 853, and DIN EN 856 10.6.1

If technically required for production machines, hoses conforming to DIN EN 857 may also be used. Minimum requirement: hose assemblies with metal-fabric sheaths (at least two layers) shall be used.

Hose fittings 10.6.2

Hose fittings with 24° sealing cone shall be executed in accordance with DIN ISO 12151-2.

Hoses with fabric sheaths 10.6.3

The use of hoses with fabric sheaths shall be coordinated with the project management and the responsible technical specialist department at Daimler.

Requirements for hose assemblies 10.6.4

The following requirements shall be complied with by the hose assemblies used: • They shall be produced from hoses that meet all performance and identification requirements

of the standards, and they shall not have been previously used as part of a different hose assembly • They shall be identified and routed as per DIN 20066 • It is not permitted to deliver hoses that were produced more than 12 months before. • Hoses shall not be used at pressures which exceed the hose manufacturer's rated pressure. • They shall not be subjected to loads which exceed the hose manufacturer's recommendations. • They shall be considered operating equipment and assigned an operating equipment identification

according to the standards

Installation 10.6.5

Hose assemblies shall be installed to guarantee the following:

• Provide the minimum length necessary to avoid sharp flexing and tensile stress of the hose during operation.

• Hoses shall not be bent at a radius smaller than the smallest recommended bending radius. • Minimize twisting of the hose during installation and use, e.g. as a result of a rotating

connector jamming. • Located or protected to prevent rubbing of the hose outer layer. • Be supported, if the weight of the hose assembly could cause impermissible strain • Located so that they are protected from heat penetration. • Routed in a straight line after the fitting over a length of 1,5 d (d = hose outside diameter)

or socket length, i.e. they shall not be bent directly after the fitting, and • Not be bundled, but routed in parallel and separated • Escaping pressurized fluid cannot reach ignition sources (shielding required).

Protection against failure 10.6.6

If the failure of a hose assembly constitutes a whiplash hazard, the hose assembly shall be restrained or shielded. If the failure of a hose assembly constitutes a hydraulic fluid ejection or fire hazard, it shall be shielded.

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11 Monitoring, control, and switching units

11.1 Fill level switches • Version with hole circle diameter as per DIN 24 557–2 • Permissible distances of the bottom switching point from the connecting flange • 155 mm (reservoir in accordance with DIN 24 339; 63 to 400 l) • 286 mm (reservoir in accordance with DIN 24 339; 630 to 1250 l) • Overflow protection • Connector, pin assignments: with M12x1 plug connection, 4-pin • Assignments of plug connection contacts as per MBN 9666-3 • Switch-on current ≤ 100 mA

11.2 Temperature switch, electronic • For monitoring of temperature in hydraulic fluid reservoirs • Measuring range -10 to +80 °C • Connector, pin assignments: with M12x1 plug connection, 4-pin • Assignments of plug connection contacts as per MBN 9666-3 • Process connection: plug connector M12x1, 4-pin, for Pt 100 in 4-wire technology • Accuracy of switch point: better than ± 1,0 °C • Media connection G ½" • Switch-on current ≤ 100 mA

11.3 Flow sensors

Electronic flow monitor with digital display 11.3.1

• Connection thread: G¼" internal thread • 2 switching outputs • Connector, pin assignment: with M12x1 plug connection, 4-pin • Assignments of plug connection contacts as per MBN 9666-3

Electronic volume sensors with digital display 11.3.2

• Threaded stud: external thread • 2 outputs • Connector, pin assignments: with M12x1 plug connection, 4-pin • Assignments of plug connection contacts as per MBN 9666-3

12 Other devices, rotary distributor/rotary feed through The use of rotary distributors/rotary feed throughs shall be coordinated with the project management and the responsible technical specialist department at Daimler.

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13 Material selection and materials subjected to cooling lubricants All materials and auxiliaries for the machine tools and production systems shall not be changed by the cooling lubricant and potential additives in terms of their chemical and physical properties. The problem lies in the relatively long exposure time under often extreme and changing operating conditions. Depending on their composition, cooling lubricants have a varying effect on the different materials and auxiliaries used within the context of machine tools. The following components come into contact with cooling lubricants: • Seals (elastomer and thermoplastic materials) • Piping materials • Slideway materials • Roller bearing materials • Sliding and roller bearing lubricants • Slideway wipers - telescopic covers - bellows - cups, sleeves • Machine paint coats and primer • Metallic materials • Electrical, mechanical, hydraulic, and pneumatic devices • Adhesives It is not possible to make a generally applicable statement in terms of material selection due to the multitude of parameters. The corresponding machine parts shall be subject to a special test with the applicable cooling lubricant if there are no empirical values for the affected cooling lubricant and potential additives to the KSS.

13.1 Sealing materials Sealing materials shall be made from fluorocarbon rubber (FKM).

13.2 Materials for pipes, hoses, and fittings • Steel pipes, chemically nickel-plated brass fittings, as well as pipes and hoses as per

MBN 9666-7 shall be used. • The use of zinc-plated steel pipes or fittings made of non-ferrous metals, e.g. copper and aluminum,

is not permitted. • Vibration-insulating elements shall be used for rigid connections. Sealing materials for fittings: designed as per VDI 3035 in combination with KSS specifications by specialist departments

13.3 Interaction of slideway materials, slideway oils/grease with KSS Materials including cast iron, soft or hardened, and steels, also soft or hardened, in combination with plastic linings, and less often with bronze supports, shall be used as slideway materials. In the case of plastic coatings, materials such as filler or pressable compositions on an epoxy resin basis are used. Other sheet or strip-type materials on the basis of PTFE, or similar, thermoplastic material compositions are also used. The following shall be taken into account during machine design to prevent the malfunction of the components and substances used. • Metal, plastic, and ceramic linings are often attached to the slideways using adhesive. If the linings

are then ground, the adhesives shall resist cooling lubricants for the duration of this process. If slideways created in this way are permanently exposed to cooling lubricants during machine operation, the adhesives shall be durable, or other, e.g. mechanical attachment, options shall be selected.

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• Increased corrosion effects and additional increases in friction values may occur if, as a result of the process or design, slideway oils/grease and cooling lubricants are mixed in or on the slideways of the machine tools. Slideway oils or greases can mix with cooling lubricant or can be washed off or away. Remnants of the mixture remain in the area of the friction partners during idle phases, causing deposits of reaction products, an increased formation of microorganisms and their metabolic products and ultimately corrosion.

• Highly water-absorbent plastic slideway linings shall not be used. • Of decisive importance to the compatibility of the slideway oils or greases with water-mixed cooling

lubricants are their demulsification properties and the cohesive as well as adhesive properties, i.e. the high adhesiveness of the slideway oil or grease.

• The selection of a suitable slideway oil/grease as per the aforementioned criteria is an essential prerequisite to ensure that neither mechanical nor corrosive wear, nor an impairment of the sliding behavior of the guides, nor additional loads on the water-mixed metalworking fluid can occur as a result of partial emulsification of the slideway oil/grease.

13.4 Coating materials for machines Due to the chemical resistance requirements, two-component coating materials with a low solvent content or free from solvents and based on epoxy resin (EP) or polyurethane resin (PUR) are recommended. The metal surface intended for coating shall be prepared prior to coating using one or more of the following methods as per DIN EN ISO 12944-4 and DIN EN ISO 9717: • Degreasing • Pickling up to surface preparation grade Be • Radiation up to surface preparation grade Sa 2 1/2 • Phosphating One-pack paints, so-called "oil resistant", simple machine coating compounds, offer no protection against "swelling" and "washing off" in combination with cooling lubricants. The limited additional effort incurred for "chemically resistant paints" (e.g. materials and labor for two-component coating materials) is in no relation to the damage and objections which arise when unsuitable protective coatings are used.

13.5 Metallic materials Some metallic materials shall not be used in the case of unavoidable contact with cooling lubricants: • Zinc-coated steel • Various aluminum alloys • Certain non-ferrous metals Leaks may also occur as a result of wear. Suitable materials or coatings shall be used in such endangered areas.

13.6 Adhesives Adhesives used in machine tool construction under the influence of cooling lubricants shall be selected in terms of their chemical/physical resistance. The resistance of adhesives to KSS shall be verified in preliminary tests. The sub-surface corrosion only partially depends on the adhesive itself; the following are decisive influences: • Type of bonded material • Surface conditions of bonded material • Time of exposure, temperature, and concentration • Geometric conditions • Applied forces

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Important aspects for the durability of a bonded joint are: • Adhesive type (e.g. based on epoxy resin/methacrylate) • Surface pre-treatment (such as cleaning, grinding, milling, sand blasting) • Degreasing the contact surfaces • Protective covers of the bonded joints with flexible paints or by ensuring that a bead is created

when gluing slideways or by adhesive escaping from the glueline followed by milling away.

14 Occupational safety and environmental protection equipment The contact between cooling lubricant and humans shall be restricted to a minimum. The limit values applicable at the installation location shall apply in terms of the total cooling lubricant aerosol content and vapors in the workplace atmosphere. These limit values shall be requested from the Daimler specialist department. Design measures shall make sure that machine tools or production systems, including their cooling lubricant circuits, are constructed to prevent uncontrolled changes to the cooling lubricant.

14.1 Technical measures for preventing skin contact Skin contact can be reduced by the following measures: • Fully automatic feed to the machine tool and production facilities using feed systems • Enclosed machine tools and production facilities • Interruption of the cooling lubricant supply prior to opening the charging door • Use of splash protection devices such as deflector panels • Removal of cooling lubricant from processed workpieces before further handling

(e.g. automatic workpiece rotation to remove cooling lubricant residue).

14.2 Encapsulation of machine tools and production facilities, and extraction and separation of cooling lubricant fluid aerosols and vapors

If the generation or spreading of vapors and aerosols from cooling lubricants cannot be avoided, e.g. due to the machining process, they shall be collected effectively at the point of generation and escape, for example by encapsulation and extraction, conveyed away safely and separately to the highest possible degree. The applicable fire protection regulations shall be observed when using non-water-miscible KSS. This equipment used for collection (collecting facilities) extracts the ambient air with the aerosols and vapors contained in it. This system of collecting facilities, air intake, and separators is called an extraction system. The air extracted using this extraction system shall then be replaced when the exhaust air is directed towards the outside.

Design of the collecting facilities 14.2.1

Collecting facilities as per VDI 2262 SHEET 4) can be broken down into the following types according to their effectiveness: • Closed type • Semi-open type • Open type

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In the case of the closed type, the application area of the cooling lubricants on the machine or system is completely enclosed (encapsulated). The housing is connected to an extraction system. Extraction air reaches the inside via the unavoidable openings in the housing, such as those for chip removal, material feed and removal. An escape of aerosols and vapors is therefore avoided. The closed type is the most effective system and also has the lowest extraction air volumes. If only one side of the housing is open, this is a semi-open design. The extraction system shall be designed so that a constant air flow is directed to the inside across the entire opening. The effectiveness of semi-open collecting facilities is significantly restricted. They are used in cases where access to the machining process is required from all sides, e.g. on rolling lines and processing machines for large surfaces. In the case of open facilities, deflector or baffle devices (deflector plates, skirts) shall be provided where appropriate. As ambient air flows back into the extraction areas, emissions from neighboring areas can be conveyed toward such workplaces. As a rule, cross flows shall be avoided throughout the area. This ensures that the extracted air is replaced directly by incoming air.

Routing of extraction air 14.2.2

Pipes and/or duct systems shall be used to route aerosol contents and vapors. Deposits of cooling lubricant can develop within these systems. To minimize such cooling lubricant deposits, air ducting systems with a gradient shall be installed. Openings shall be provided for cleaning, or the line systems shall be designed so they can be dismantled. This applies in particular to horizontal lines or ducts as well as transitions and branches. Seals within the system shall be resistant to cooling lubricants.

Separation of aerosol contents and vapors 14.2.3

Filtering, electrostatic, and wet separation systems shall be used to separate aerosols and vapors. Aerosols are significantly easier to separate than vapors. However, some separation methods do not allow vapors to be separated at all or only to an insufficient degree. The selection of the separating method is determined primarily by the ratio of aerosol to vapor in the extraction air. The following represents a list of additional selection features: • Type of cooling lubricant (non-water-miscible or water-mixed) • System size or height of the extraction air flow • Operating principle (continuous or discontinuous) "Workplace air - Reduction of exposure to air pollutants - Ventilation technical measures" as per VDI 2262 SHEET 3.

14.3 Environmental protection systems (directives and regulations) The requirements for installations, such as systems, tanks, pipes, and hoses, are basically determined by the potential hazards arising from the cooling lubricants used and by water and environmental protection legislation. The installations shall be built, installed and operated as per the basic requirements, taking into account the duty of care, and shall comply at least with the generally applicable technical rules. Any additional, special safety precautions shall result from the assignment to systems to produce, handle, or use goods (HBV systems). Use shall represent the application, use, and consumption of substances hazardous to water by taking advantage of their properties.

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Depending on the system volume and the water contamination class of the KSS used, the requirements shall be determined by the following: • Surfacing and sealing of floor areas • Retention capacity for escaping water-polluting liquids • Infrastructure measures of an organizational or technical nature

15 Maintenance, cleaning and care Chemical reactions can negatively influence the pot life and performance of cooling lubricants. Inspections, maintenance, cleaning, and care of the KSS and the circulation system, as per Figure 1, are therefore essential. Maintenance recommendations shall be stated. Incompatibilities, such as those listed in the sections from "Seals" to "Electrical components", shall be taken into account. Cooling lubricant circuits shall be designed and positioned so that they are easily accessible and can be maintained, cleaned, and cared for without causing any hazards. Options and facilities shall be created to enable necessary statutory monitoring in an easy and cost-effective way, e.g. by measuring consumption and supply points. Good accessibility for maintenance work involving all line and machine elements carrying or coming into contact with KSS shall be provided, e.g. clearly visible mounting of equipment and lines, maintenance openings, installations, such as lines, valves, etc., shall not be installed in a concealed way on the inside "but on the outside of the machine or system". An appropriate design of openings, covers, etc. should make it possible for maintenance work to be carried out without the need for additional dismantling. Easy replacement of seals and wearing parts on the machines and installations shall be possible. The connections (type, size) for mobile or stationary additional equipment, such as for inspection, maintenance, cleaning, care, and filling, shall be coordinated between the contractor (machine supplier) and client (Daimler specialist department). The technical documentation for maintenance, cleaning, and care, such as inspection and maintenance instructions when using KSS, shall be included with the operating manual.

15.1 Cooling lubrication documents Documents shall be submitted to the responsible technical Daimler specialist department, which shall examine, assess, and approve them! Cooling lubrication circuit diagram, list of equipment, cooling lubrication point plan (action points of the KSS nozzles on the workpiece, tool, working facilities, bed rails, etc.), electrical circuit diagram, as well as a description of the cooling lubricant cleaning equipment. For the cooling lubrication plan and the related lists of equipment, the formats according to ISO 1219-1 and -2 shall be employed.

Lubrication data sheet 15.1.1

The lubrication data sheet, which shall be available in its corrected version at least 6 weeks prior to delivery of the machine, shall document all cooling lubricant data required to operate the machines. In this process, the GGA list of the approved substances within individual plants/locations shall be observed. For technically justifiable deviations, written approval applications (GGA approval applications) shall be submitted to the respective plant.

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Cooling lubrication circuit diagram 15.1.2

The individual components shall be shown in the initial condition of the control system. If the symbolic representation of a device is insufficient, a simplified representation of the device with the clearly recognizable operating principle shall be chosen. The following data shall be included: • Identification of all component parts by the numbers corresponding to the equipment list • Dimensions of pipes and hoses • Hose assemblies shall be drawn in the diagram and uniquely labeled with the list item numbers.

The hose assemblies shall be documented in the list of equipment including their list item number, type, length, and manufacturer data.

• Performance data of the pump drive (delivery rate, pressure range, rotational speed, etc.) • Pressure setting in bar for pressure switches • Temperatures • Capacity of the cooling lubricant tank • Filter fineness grades

15.2 List of equipment (component part list) Each cooling lubricant circuit diagram, with an associated list of equipment, shall be provided as per ISO 1219-1 and -2.