Spline Shaft Washer – Case Study 21872

Mini Conveyor Washer C-6
Spline Shaft Washer C-6
Spline Shaft Washer C-6

Spline Shaft Cleaning
Background

This company is a leading American manufacturer of automotive electrical components, instrument clusters, power-train systems, and automotive electronic products. Their products are used by major U.S. automobile manufacturers. One of the components they make is spline shafts. They wanted a new spline shaft washer to integrate into their manufacturing process.

Parts Cleaning Challenge

They needed to remove chips and oils from the shafts after the milling process. They also needed a parts washer that that would fit into their existing work cell (between a knurling machine and an induction heating unit).

Solution/System

The solution was a custom, compact spline shaft washer with a 6″ wide conveyor belt. Side rails keep shafts aligned on the belt. The overall system length is only 70 inches. All wetted parts are grade 304 stainless steel with an insulation cladding covering. The system runs off of 110V power.

The customer’s pick and place unit automatically places the shafts onto the washer’s conveyor. The parts get washed, blown off, and then slide down a chute into the customer’s vibratory conveyor.

System features include a 75-gallon tank with automatic water level controls, a compressed air blow-off stage, a 2HP pump, a steam exhaust system, a NEMA-12 control panel, 7-day/24-hour timer, a digital thermostat for the heat tank, a variable speed controller for the conveyor belt, a lid interlock switch, and removable filter basket.

Please contact us to learn about more cleaning applications and systems like this!

Small Ammunition Cleaning – Case Study 21130

D-24 5-stage drum washer small ammunition cleaning
Drum Washer
Drum Washer

Background:

Small ammunition cleaning is imperative to remove chips and cutting oils in the manufacturing process in order to achieve optimal product safety and reliability. This company is a key ammunition manufacturer for the defense, aerospace, security, and outdoor sports industries and they needed to clean 7.62mm brass shell casings.

Parts Cleaning Problem:

They were using 70-year-old parts washers that no longer cleaned their parts efficiently or effectively.  They needed a new small ammunition cleaning system to clean the shell casings after heat treatment.

The System/Solution:

The solution was a 5-stage D-24 Drum Washer with a 24-inch diameter drum that cleans shell casings after heat treatment.

The system outputs 40,000 shells per hour. Shells are put through the following 5 stages: acid pickling to remove the heat treatment scale, rinse, rinse, lube, and dry. All wetted parts of the system are stainless steel. The drum has “scoops” to bring the fluid into the drum (there are no pumps). In the wet stages, the shells are fully immersed. The system processes 30-35 lbs. of shell casings per minute.

Features include gas heat for the dryers, marine cleanout doors for each tank, a steam exhaust system, and an Allen Bradley Micrologix PLC and Panelview.

Please visit our Drum Washers page or contact us to learn more about cleaning applications and systems like this!

Precision Cleaning Jet Engine Parts – Case Study 21805

turntable washer for aerospace cleaning
Jet Engine Parts Cleaning System RD-6000-PCS
Jet Engine Parts Cleaning System RD-6000-PCS

Background

This company is a leading American aerospace manufacturer with global service operations. Their aircraft engines are widely used in both civil aviation and military aviation. Jet engine parts cleaning is critical to ensure optimal product safety and performance.

Parts Cleaning Challenge

They needed an aqueous parts washer for final, precision cleaning of critical jet engine components.

Solution/System

The solution was twin, automated precision cleaning systems. Each unit has a 60-inch diameter turntable and a 60-inch working height with a roll-in door. The system also has two identical 300-gallon tanks for high volume wash and rinse stages, as well as fresh-rinse and dry stages.

The parts being cleaned can be as large as 55-inches in diameter and have internal cavities. A center-drop spray/dry manifold automatically lowers into the parts to clean the inner diameter.

Other features include a part collision sensor for the ID manifold, all stainless steel construction, steam heat for the tanks, a steam exhaust system and mist collector, a vacuum system, a viewing window, a mist collector, a 20HP regenerative blower with sound shield, a 10″ HMI screen, and more.

Please contact us to learn about more cleaning applications and systems like this!

Parts Cleaning System for Gas Cylinders – Case Study 21734

Gas Cylinder Cleaning System RTO-2000-PCS
Gas Cylinder Cleaning System
Gas Cylinder Cleaning System

Cleaning Gas Cylinders w/ Automated Passivation System
Background

This company is the world’s largest manufacturer of aluminum high-pressure gas cylinders. Their products are used in a wide variety of industries including SCBA, SCUBA, performance racing, medical, transportation, alternative fuel, beverage, life support, and more. Efficiently cleaning gas cylinders is critical.

Parts Cleaning Challenge

They needed a system for cleaning and passivating multiple gas cylinders in the final manufacturing process. They also required a system to integrate with their existing robotic work cell.

Solution/System

The solution was a return-to-operator system RTO-2000-PCS. This extraordinary machine cleans/passivates gas cylinders inside and out. The system has six individual cleaning chambers, each with a vertical, powered door and automatic valves to control flows from 3 tanks and air blow-off. The parts are loaded and unloaded with a robot. A top pneumatic device secures the part before the robot lets go. Another pneumatic device inserts a nozzle through the part orifice. In each chamber, the parts undergo a 5-step process:

  1. wash with fluid “A”
  2. rinse
  3. wash with fluid “B”
  4. rinse
  5. dry

Other system features include stainless steel construction, custom fixturing, ID spray nozzle, automatic water level controls, a steam exhaust system, safety sensors, sump pump/sump tank, and NEMA-12 control station with PLC.

Please contact us to learn about more cleaning applications and systems like this!

Long Spray Washer for Jet Engine Rotors – Case Study 21766

Impulse-80 Long Spray Washer
Long Spray Washer Impulse-80
Long Spray Washer Impulse-80

Impulse Wide-80
Background

This company is a leading provider of jet engines, components, and integrated systems for commercial and military aircraft. They were looking for a long spray washer to accommodate jet engine rotors.

Parts Cleaning Challenge

The company was using an older spray washer and needed to replace it with a system that would be able to clean all areas of a rotor.

Solution/System

The Impulse Wide-80 is a top-loading spray washer and is designed to automatically clean jet engine rotors in a horizontal orientation. The work envelope is 80″ long x 33″ in diameter and the overall weight capacity is 2,000 lbs. This is a fully automatic, two-stage wash/dry system with spray and dry manifolds that oscillate around the rotor (the rotor remains stationary). The unit has two, plastic-lined “V” fixtures that move laterally and adjust vertically for different parts. The lid is powered up and down with pneumatic cylinders and opens at 90° for complete overhead access. A 12.8 kW air heater automatically dries parts with compressed air.

The system has a 400-gallon wash tank with a 15 HP vertical, seal-less pump. Particles and oils are filtered out of the heated wash tank through an in-line micron filtration system and an oil/water coalescer. All wetted parts on the machine are stainless steel with 1-inch insulation covering the steel panels.

Additional system features include a steam exhaust system, mist collector, automatic water level controls, timers for wash and dry stages, and a NEMA-12 central control station.

Please contact us to learn about more cleaning applications and systems like this!

Jet Engine Exhaust Rings Parts Washer – Case Study 21480

Jet Engine Exhaust Ring Parts Washer F-4000LX-ULT
Jet Engine Exhaust Ring Parts Washer F-4000LX-ULT
Jet Engine Exhaust Ring Parts Washer F-4000LX-ULT

F-4000LX-PCS Parts Washer

Background

This company specializes in aerospace sheet metal fabrication and design for complex aerospace applications. They are a supplier to the world’s major, leading aircraft and aerospace engine manufacturers. They were in need of a jet engine exhaust rings parts washer to shrouds in the manufacturing process.

Parts Cleaning Challenge

Their old system was having issues with particulates coming off of the inside surface and depositing on their parts. They needed a stainless steel precision cleaning system to keep this from happening and to meet stringent aerospace cleaning requirements.

Solution/System

They purchased the F-4000LX-PCS jet engine exhaust rings parts washer to clean the shrouds.  Each part is approximately 36” in diameter and 27” in height.  To clean the inner diameter to the same degree as the outer diameter, a powered spray/ dry manifold gets automatically lowered into the center of the parts. This stainless steel system has two high-volume tanks with wash and rinse stages and a 10HP regenerative blower for a heated dry stage.

Additional system features include a steam exhaust system, mist collector, micron filtration system, full insulation, automatic waster level controls and auto-fill, vertical seal-less pumps, oil/waster coalescer, and a central control station with a PLC, 10″ HMI, and main disconnect.

Please contact us to learn about more cleaning applications and systems like this!

Fuel Injector Parts Cleaning – Case Study 21780

Dual Conveyor Tumbling Washer
CJ-2 fuel injector parts cleaning system
CJ-2 fuel injector parts cleaning system

Background

This company is a leading manufacturer of automotive air conditioning and engine cooling components and systems. Part of their manufacturing process requires fuel injector parts cleaning to remove chips and oils.

Cleaning Challenge

The company was expanding and needed new parts washers to integrate with a new, lean manufacturing work cell.

Solution

This CJ-2 cleans fuel injector parts to the highest possible standards. This system cleans trays of parts since this is how they are normally handled in the manufacturing plant. The operator places a tray (single or double stacked) on the blue conveyor belt and walks away.

The conveyor then automatically loads and unloads the trays into the CJ-2 cleaning chamber which can clean up to 4 trays per cycle. In cycle, the trays are orbiting in and out of the wash and rinse solutions, and progress through a multi-stage cleaning sequence which includes spray wash, ultrasonic wash, spray rinse, ultrasonic rinse, and drying. Finished trays queue to the unload end of the conveyor for pick-up.

Additional system features include a 1000kW ultrasonic cleaning system, automatic loading and unloading of parts, a regenerative blower with sound shield for automatic drying stage, a steam exhaust system, sump tank and sump pump, an oil skimmer, and a central control station with PLC and 10″ HMI.

Please contact us to learn about more cleaning applications like this!

Conveyor Washer Large Metal Stampings – Case Study 20796

conveyor washer for large metal stampings
Conveyor Washer for Large Metal Stampings
Conveyor Washer for Large Metal Stampings

Background

This company specializes in large metal stampings such as dome covers for pressure tanks. They are cleaning air compressor end caps and blind caps. A large portion of their parts are as large as 48″ diameter x 16″ high. They wanted a large metal stampings conveyor washer to handle these large parts.

Cleaning Challenge

They needed to replace an aging parts washer with a high-speed (45 FPM) conveyor washer to remove a heavy coating of lubricant, as well as most of the black residue, from the hot rolled steel parts. The system also had to handle the chlorinated paraffin lubricant which tends to foam and which largely sinks to the bottom of the tanks.

Solution

The solution was a super-powerful C-48 metal stampings conveyor washer with a 50″ wide x 19″ high work envelope. This stainless steel system has two modules (pre-wash and final wash), two 2,000 gallon tanks, and a total of six pumps. Each pump has an output of 300 GPM at 60 PSI for a total flow of 1800 GPM!

Additional system features include chain belting, gas heat, a steam exhaust system, two separate oil/water coalescers, non-electric chemical injectors, and a central control station.

Please contact us to learn about more cleaning applications like this!

Cleaning Pharma Capsule Printers – Case Study 20667

pharma turntable washer
Turntable washer for pharma cleaning
Turntable washer for pharma cleaning

Background

This company manufactures and sells two-piece, hard gelatin drug capsules that pharmaceutical and nutraceutical companies use for their products. The company wanted an automatic parts washer to make their pharma cleaning process more efficient and effective.

Cleaning Challenge

The print on these tiny capsules is applied by special printing machines and these machines need to be cleaned on a regular basis.  The machinery gets completely torn down and every component is methodically washed.  This process was being done by hand at great expense.

Solution

The solution was an F-3000-P turntable washer with special user-friendly racks that protect the delicate parts (especially the print rollers) from getting scratched.  This stainless steel unit has a 30-inch diameter turntable and special fixtures to hold the parts. The system processes the parts through wash and rinse stages. Parts are washed at over 180° for sanitizing to help prevent cross-contamination between batches. A center-drop manifold helps ensure that the parts are cleaned on all sides.

Additional system features include a dual-channel 7-day/24-hour timer, low water shutdown and automatic fill, a fresh rinse cycle with automatic diversion, in-line micron filtration, and an oil skimmer.

Please contact us to learn about more cleaning applications like this!

Camshaft Cleaning System, Robotic Automation – Case Study 21825

Conveyor Washer Loop Table Top Chain
camshaft-conveyor-washer
Camshaft Conveyor Washer

Background

This company is a leading American manufacturer of heavy-duty trucks and powertrain systems. They needed an automated camshaft cleaning system to clean the parts after the machining process.

Cleaning Challenge

The parts cleaning system needed to integrate with their existing robotic work cell.

Solution

The solution was a Cyberjet C-14 fully automated parts washing system that cleans diesel engine camshafts. A single robot loads and unloads the camshafts on one end of the system. Once a camshaft is loaded onto a fixture, the fixture is released and the part travels around the tight radius, closed-loop conveyor.

The parts stop at various queuing stations and then travel through a wash zone, a dry zone, and then an oil misting zone (not all parts are misted. The system knows which parts do and don’t get coated with oil.) The power drying module has a 5HP centrifugal blower and an 18kW air heater.

Features of the camshaft cleaning system include stainless steel construction, five automatic stops, a heated wash tank, high-velocity air knives for drying (air is heated), inline micron filtration, a marine cleanout door, and a mist collection system for the oil misting section.

Please contact us to learn about more cleaning applications like this!