High production volume, always the same component — and still it is deburred by hand.
Stationary Water Jet Deburring System
1 · The challenge
The task here is not complexity, but repetition
Where this problem occurs
Predominantly aluminum die casting. For this concept, those among them come into question that run in a constant version and production volume.
Which burrs are meant
Even without a movable jet guidance, the jet reaches burrs at and in bores — the nozzle only has to stand correctly once. There is no fixed standard burr type; what counts is the part geometry.
2 · Engineering considerations
The decisive question is: does anything change?
What is assessed for this are burr root, accessibility of the deburring locations, material, part geometry, size and weight, cycle time, residual contamination requirement, workpiece fixture and degree of automation.
The material is rarely the decisive factor. Aluminum, steel, stainless steel, brass, copper, zinc die casting and plastic can all be processed.
A trade-off we address openly: this configuration is the most cost-effective as long as the component stays the same — and the least flexible as soon as it changes. If new components are foreseeable, that belongs in the decision, not in the follow-up conversation.
With ITR, the robot solution is the standard. We design without a robot when a fixed clamping position and cost-effectiveness speak for it — that is a reasoned decision, not a saving in the wrong place. The stationary system is a fully fledged standard concept, not a makeshift.
3 · The machine concept
Fixed nozzle systems, designed for one component in one position
The nozzles sit where the deburring locations are — designed for this one component in this one position. We work with standard nozzles and design and manufacture our own nozzle geometries when the application requires it.
That shifts the engineering work forward. With the robot cell, the path is programmed and can be adapted later. Here the nozzle arrangement is designed — it has to be right the first time.
The clamping fixture carries more responsibility here than usual. Because the nozzles are fixed, the component has to sit exactly and repeatably in the same position. A deviation that a robot could compensate goes straight into the result here. Standard are pneumatic clamping fixtures.
The water circuit is closed. Filtration is part of every system; we integrate more extensive water treatment depending on the project. Safety technology according to risk assessment.
Where the concept is extended
- 01
Barcode and DataMatrix systems
Component identification and traceability. - 02
Automatic loading
- 03
Line integration with further systems
- 04
Rotary table
Depending on the project.
Vision system and tool changer belong to the range of options of the robot cells; whether they can be used sensibly here is a question of the individual case.
4 · The result — and its verification
Two results are verified: residual burr and residual contamination
With a fixed process, process monitoring is particularly effective: if nothing is supposed to change, every deviation is a signal.
When another solution fits
Fixed nozzles are designed for one component
- 01
Single-robot cell
As soon as different components are to run over the system, or the geometries are complex and the deburring locations spread out. - 02
Dual-robot cell
With very short cycle times and high production output. - 03
Rotary indexing water jet deburring system (special solution)
When setup and clamping time are considerable in relation to the processing time.
Limits of the method
Water jet deburring is not automatically the best solution
Defined chamfers or radii are required
The method removes burrs, it does not replace machining — the jet does not shape the edge.Very firmly adhering or massive burrs
They have to be eliminated differently, by design or by manufacturing.The deburring location cannot be reached with any nozzle concept
Whether it can be reached is decided by the geometry, not by the size of the burr.It is not economically viable
For example at very small production volumes, or when a simpler deburring method is sufficient.Another method meets the requirements better
Technically or economically.
Scope of supply
The scope of supply is defined project-specifically
Questions and answers
Frequently asked questions about the stationary system
When is a stationary deburring system the right choice?
How is a stationary deburring system built?
Applications
Components on which this system design is decided
Each case sets out the design factors, the possible system concepts and the methods in detail — here you only find what it is about.
Hydraulic manifold
The channels are drilled, they intersect several times, and at every bore intersection a burr forms.
Valve block
The burr root sits at the bore intersection of two bores — no tool gets there, not because it would be too big, but because no path leads to it.
Components with heavy burrs
Casting flash and metal fines do not sit on one edge but spread out — and later they come loose by themselves.
None of these cases inevitably leads to the stationary deburring machine. Which concept it becomes arises from the interplay of the design factors — the machine type is the result of the system design, not its starting point.
Direct contact
Hauptstraße 31
93186 Pettendorf
Pettendorf bei Regensburg
Fax +49 (0) 9409-777 3607