Problem
Aluminum battery cases leave the stamping process carrying lubricants, aluminum chips, and other residue that must be fully removed before assembly. At roughly 56″ wide and 81″ long, the cases are large, relatively thin parts, which makes consistent handling as important as the wash itself. Any movement during the cycle can affect spray coverage and part positioning for downstream automation.
The customer needed a system that could hold each case securely through every stage, deliver enough spray volume and heat to remove stamping residue consistently, dry parts completely, and do it continuously at production speed.
Solution
Better Engineering engineered an M-14 continuous monorail parts washer with a single-lane, full-loop monorail that carries parts through the system and returns empty fixtures to the front of the machine. The system runs at a 53-second takt time, with the monorail pausing for 10 seconds to allow robotic loading and unloading at separate stations along the line.
Battery cases are robotically loaded into custom “encapsulating” fixtures: slip-fit fixtures with a metal body that fully encloses each part. Fixture inserts accommodate multiple battery case sizes, and eight fixtures travel the loop on approximately 14-foot centers. At both the load and unload stations, shot-pin structures lock each fixture into position, minimizing movement and ensuring precise, repeatable part positioning for the robot.
Once loaded, each battery case passes through two process stages:
- Heated recirculated wash: A high-volume spray system delivers approximately 200 GPM at 60 PSI, removing stamping lubricants and aluminum chips with heated solution up to 140°F. A large-capacity tank with automatic water level controls and bag filtration maintains consistent operating conditions throughout production.
- Heated dry: High-velocity blowers and air knives deliver heated air up to 250°F, so every battery case exits clean, dry, and ready for the next manufacturing operation.
The system uses 304 stainless steel wetted components, runs on 480V three-phase power, and is built on a modular platform with bolt-together, flanged sections that simplify installation and transportation and allow the line to expand as production demands evolve.
Results
The completed monorail washer gives the customer a continuous, automated cleaning process that keeps pace with high-volume battery case production. Robotic loading, encapsulating fixtures, and shot-pin locating keep every part stable and precisely positioned, while the heated wash and heated dry stages deliver clean, dry battery cases to the next operation at a 53-second takt time.
Performance Highlights:
- Production-speed throughput: A single-lane, full-loop continuous monorail runs at a 53-second takt time.
- Secure, repeatable handling: Encapsulating fixtures fully enclose each battery case, with shot-pin locating at the load and unload stations for automated robot handling.
- High-volume heated wash: Approximately 200 GPM at 60 PSI with heated solution up to 140°F and bag filtration removes stamping lubricants and aluminum chips.
- Complete dry cycle: Heated blowers and air knives reach up to 250°F so parts exit fully dry.
- Built to grow: Modular, bolt-together construction simplifies installation and supports future expansion
Conclusion
In battery production, clean components are essential to product quality, manufacturing efficiency, and long-term performance. By pairing a continuous full-loop monorail with robotic loading, encapsulating fixtures, a high-volume heated wash, and a heated dry stage on its M-14 platform, Better Engineering delivered a wash system that cleans aluminum battery cases at production speed.
Interested in finding your solution? Contact us for more information, a facility tour, or free part testing.