Manufacturing

Customer
Automotive Manufacturing

Application
Brake Parts

Background
This internationally known company is the oldest tier-one supplier of automotive componentry in the world. They are world renown for their advancements in airbag, wiper blade, and braking system technology. Since 1994, they have purchased several machines from Better Engineering for a number of diversified applications. At this particular plant they are manufacturing anchor plates for caliper brakes. These parts measure 12” high, 12” long, and are 1” high.

Problem
This application presented Better Engineering with several challenges. First, following machining, the anchor plates had to be transported, via forklift, to a separate cleaning station. Secondly, they needed to be able to sufficiently wash and dry the anchor plates using an aqueous solution; the previous cleaning method of vapor degreasing was inadequate and presented environmental issues. Lastly, because of space contraints, a belt washer with a return conveyor would have been problematic.

Solution
A “cell machining center” was designed which intergrated the machining operation with the washing and drying function. This system consisted of a “Carousel” washer which has the front of the turntable exposed for loading and unloading. The operator loads the newly machined anchor plates into the Carousel washer and unloads them at his convenience. The turntable rotates very slowly - about 5 minutes per rotation in this case - moving the parts thru a “wash” zone and then a “dry” zone. By the time the parts come back around, they are clean, dry, and ready to be packaged and shipped.

The operator doesn’t care if the parts went around once or several times. He knows that any parts coming through the exit curtain are clean and can be removed.

System
A carousel system, C-7000-P (70” diameter turntable) with wash and dry zones and a special fixturing rail to support the customers heavy parts. For drying, the machine has a 15 HP regenerative blower, a 35 KW air heating system, and a “Mist-Kop” self condensing steam eliminator; avoiding the hassle of running a vent line.

3/11/97