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Vapormatt Oncilla Machine Technical Brochure (BL-243-B)
Vapormatt Oncilla Machine Technical Brochure (BL-243-B)
The Oncilla is an advanced wet blasting system designed for preparing round shank tools like solid carbide end mills, drill bits, and taps for vacuum coating. It supports various production capacities and cleanliness standards, ensuring tools are ready for PVD and CVD coating processes. The system is robotic, enhancing repeatability and reliability, and features a robust stainless steel cabinet with advanced monitoring systems. Its configurable design allows for tasks like edge preparation and surface activation.
- Stainless steel blast cabinet with a large viewing window.
- Consistent edge hones with homogenous edge radii within +/- 3µm.
- Preparation for PVD and CVD coating processes, achieving HF-1 adhesion levels.
- Capability to develop and store multiple blast recipes.
- Accommodates tools with diameters of 3 - 25.4mm and lengths of 46 - 204mm.
- Blast gun innovations for targeted blast streams.
- Intuitive color HMI for easy setup and operation.
- Recipe-driven parameter setting and post-process reporting.
- Vapormatt 4.0 enabled for remote diagnostics.
The Oncilla system is versatile, offering consistent processing results across the round shank tool industry. Applications include component cleaning, edge honing, preparation for coating, and surface activation for PVD/CVD coatings.
The Oncilla system provides repeatability in preparing round shank tools, suitable for medium to high volume production. It features a stainless steel construction for a robust and quiet structure. The process involves loading tools onto a pallet, moving them to the blasting station, and then through rinsing and drying stages. The system allows for operator intervention and is controlled via an HMI panel.
- Wet blast for macro blasting.
- Blow off with compressed air.
- Rinse with recirculated water.
- Optional ultrasonic and deionised water rinses.
- Drying with an air blower.
- Constructed from welded stainless steel with large maintenance access doors.
- IP54 electrical control system with Rockwell components and Allen-Bradley PLC.
- Overhead gantry robot with fast and accurate servo-driven axes.
- Y-Axis loader and unloader for greater tool volume processing.
- Pneumatic 180˚ flipper and effector jaw for tool handling.
- 4kW slurry pump and Vapormatt blast guns for consistent blasting.
- Abrasive fines removal and blow off systems.
- Recirculated rinse station and drying station.
- Cabinet exhaust system and programmable ANDON status beacon.
- Translation of operation manual and HMI screen.
- Stainless steel cover panels for enhanced aesthetics.
- Second blast station for consecutive processes.
- Effector jaws for different shank diameters.
- Additional tool pallets and slurry system enhancements.
- Ultrasonic cleaning tank and deionised water rinse.
- Final rinse tank immersion heater and pump to waste system.
- Exhaust extractor for maintaining negative pressure.
The machine includes a forced centrifugal extraction unit to maintain negative pressure, with a filter unit to remove mist and dust, allowing exhaust to the workshop atmosphere. An additive dosing system is included.
A wet and dry vacuum cleaner facilitates the emptying of sediment filter tanks and other machine areas during cleaning and maintenance.
Tool-specific rinse and blow-off nozzles are fitted for coolant channel maintenance. A helical tool profile program is available for blast station 1, using a laser system to guide the blast nozzle. Micro nozzles are available for efficient blasting of tools with diameters under 6mm or helical profiles.
A barcode scanner enables automatic loading of recipes from batch cards. A Manufacturing Execution System (MES) logs machine status during the wet blasting process.
Electricity supply requires 400/480V, 3-phase, 50/60Hz. Air supply needs pressure of 6-7 bar, with specific flow rates for different guns. Town water supply should be drinking quality, with specific pressure and volume requirements. Drainage requires a floor-level grit trap. Networking involves a closed Ethernet network with internet connection for remote access.
Each customer is assigned a dedicated project leader from order to installation, ensuring machines operate to agreed specifications. The technical acceptance process includes QA checks, Factory Acceptance Testing (FAT), and Site Acceptance Testing (SAT). Process development, commissioning, and training are provided to establish recipes and ensure proper operation and maintenance.
Catalog excerpts
Vapormatt Overview, technical specifications and options
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VapormattOverview The Oncilla is an innovative wet blasting system designed to consistently and automatically prepare for round shank tools including solid carbide end mills, drill bits, and taps, for vacuum coating. The machine can cater to a diverse range of customers with varying production capacities, batch sizes, and cleanliness standards. When processed to these quality standards, these tools are well-prepared for subsequent PVD and CVD coating processes. As a robotic system, the Oncilla enhances repeatability and ensures reliability through its robust, prefabricated stainless steel cabinet,...
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Processing description The operator places a multiple-line pallet loaded with tools on the Y-axis load station. The pallet of tools is moved into position underneath the gantry robot, it picks up from the pallet by the base of the tool without touching the cutting edges. The robot moves the tool to the blasting station and lowers the tool facing downward into the blast stream for processing, air knives blow off most of the abrasive before moving to the next stage. Depending on the configurable options selected the robot could move to a second blasting process or if this option is not selected...
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Process stages Stage Chemical dosing Water purity (µS/cm) Removal of most abrasive from tools Recirculated towns water Removal of most abrasive from tools to prevent contamination between blast stations (if selected) Micro/Macro blasting Recirculated towns water Ultrasonic rinse* Clean water Improved rinse to allow direct transfer to coating Deionised water rinse* Clean water Polish rinse Macro blasting Removal of most abrasive from tools Removal of abrasive from tools Drying to avoid staining or corrosion or cobalt leaching O = dependent on options specified. * = optional. Indicative TAKT time...
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The following features are included within the machines basic price.
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The following features are included within the machine's basic specification.
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The following features are included within the machine's basic specification.
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Services to be provided by the customer The following services are required for the machine to be run correctly. The Factory Acceptance The installation and Testing will be at the site commissioning of the of manufacture. Managed machine will be undertaken by the Project Manager by the Commissioning in conjunction with the Engineer following delivery Commissioning Engineer. to site. Following delivery and The training module commissioning, the Site will cover operation, Acceptance Testing every day maintenance will happen and be and recipe fine tuning. managed by the same Commissioning Engineer....
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