System for Automated Vessel Cleaning in a Sensitive Environment
To optimize and secure its maintenance operations, a major player in the defense industry commissioned IRIAN MECATRONICS. The mission was to design and manufacture a complete set of machines for cleaning vessels used in the manufacturing of a sensitive energetic product. Our integrated solution, designed for an ATEX environment, aims to increase productivity, improve ergonomics, and ensure operator safety.
The Challenge: Overcoming Manual Cleaning Risks in an ATEX Environment
The manual cleaning of the production vessels presented several major challenges, requiring a complete process overhaul:
- Productivity and Repeatability: The manual process was time-consuming and lacked repeatability, directly impacting production cycles.
- Operator Safety: Handling solvents and exposure to product residue required a solution that limited direct operator contact.
- Ergonomics: Handling heavy parts, such as the bottom valve, required adapted tools to reduce physical strain.
- Adaptability: The solution needed to be compatible with several vessel models of different sizes (150 and 420 gallons).
- ATEX Environment: All equipment had to be designed to operate safely in a potentially explosive atmosphere.
Our Solution: A Complete, Ergonomic Cleaning Line for ATEX Zones
Our engineering department designed an ecosystem of custom-made machines, creating a complete and coherent cleaning line:
- Vessel Wall Cleaning Machine: An automatic machine forms the core of the system. Its cleaning head, equipped with conductive brushes, adapts to the vessel’s diameter. Spray nozzles and a cover connected to a ventilation system ensure efficient and safe cleaning in an ATEX environment.
- Bottom Valve Disassembly/Assembly Tooling: A mobile chassis integrates a self-contained hydraulic power unit and a cylinder for the effortless disassembly and reassembly of the bottom valve, drastically improving ergonomics.
- Gooseneck Cleaning Machine: A semi-automatic system with brushes, scrapers, and a rotating washing head moves inside the gooseneck pipe for a thorough cleaning. The system includes a solvent recirculation and settling tank.
- Ergonomic Workstation: A custom workstation with a stainless-steel surface and an extraction back panel was designed for the safe cleaning of the bottom valves, with an extraction speed compliant with safety recommendations.
Examples of our Custom Designs
