Key Reasons for Implementation

• Reduction in workpiece cooling time from 20–30 minutes to approximately 9 minutes
• Portable design allowing the unit to be moved and set up wherever spraying is required
• Integrated control box enabling easy switching between automatic and manual operation and simple setting of spray and pause durations
• Efficient automatic spray operation with minimal capital investment

Challenges Faced by the Customer

At a plant manufacturing undercarriage components for transportation equipment, reducing production cycle time had become a key challenge.

After casting, each workpiece underwent shot blasting for initial surface preparation, followed by CNC machining operations such as cutting and drilling. A further surface-finishing process was then performed to achieve the required finish.
The cooling time required after this process was a major obstacle to reducing cycle time.

The workpieces were made of cast iron and weighed approximately 30 kg each. During surface treatment, friction raised each workpiece’s surface temperature to 150°C (302°F), so it had to be cooled to 60°C (140°F) before operators could handle it manually in the next process.

Previously, the workpieces were left to cool naturally on the line, taking 20 to 30 minutes to reach 60°C. This cooling time significantly reduced overall production efficiency, and the plant repeatedly failed to meet its daily production targets.

Conventional water-spray or immersion cooling would have required drainage systems, water temperature control, and drying equipment, resulting in substantial capital investment.

The customer therefore sought a method that could cool the workpieces gradually, minimize the risk of damage from rapid cooling, and require only minimal additional equipment. Given IKEUCHI’s proven track record in industrial mist cooling systems, the customer approached IKEUCHI for a solution.

Solutions Proposed by IKEUCHI

After reviewing the application, IKEUCHI selected a BIMV Series pneumatic spray nozzle, which atomizes water with compressed air to produce a fine mist. As the mist evaporates, it absorbs heat from the workpiece, providing effective cooling.
IKEUCHI then proposed a spray cooling system combining the BIMV nozzle with a portable automatic spray unit.

The portable automatic spray unit consists of a pressurized water tank and a spray control box mounted on a wheeled frame. Measuring approximately 970 mm high, 370 mm wide, and 370 mm deep, the compact unit can be moved and positioned wherever needed on the production floor.

Three features make the unit especially practical:

• The portable unit can be moved and set up wherever spraying is required. It is ready for use once connected to a compressed-air supply and power source.
• The control box includes a start button, an automatic/manual selector switch, and separate timers for setting the spray and pause durations, allowing operators to adjust the operating cycle easily.
• A wide range of optional nozzle-mounting accessories supports layouts tailored to each production site.

Benefits Achieved

Following the proposal, IKEUCHI conducted a spray test under conditions reflecting the actual production environment. The test used air pressure higher than the standard setting, liquid pressure kept to a minimum, and a spray distance of 150 mm from the workpiece. The results confirmed sufficient cooling performance, leading the customer to adopt the system.

With natural cooling, lowering the workpiece surface temperature from 150°C to 60°C took 20 to 30 minutes. Mist cooling reduced this time to approximately 9 minutes.
This significantly shortened overall cycle time and improved productivity without requiring major capital investment.

Today, IKEUCHI’s spray nozzle products continue to support stable, efficient production of undercarriage components for transportation equipment.

SDG Contributions

Relevant SDG goals for this case.