Carousel Washer for Transaxle Parts – Case Study 21442

RTO Carousel Washer
carousel washer
Carousel Washer

Background

This company is an American manufacturer of automobile driveline and drivetrain components and systems and a leading tier 1 automotive supplier to companies worldwide.

Cleaning Challenge

They needed a 3-stage cleaning system that fits into their existing work cell.

Solution

The solution was a carousel washer with four small turntables mounted to a large 60″ diameter carousel turntable. One turntable can be loaded/unloaded by the operator while the other turntables are rotating in the wash, rinse, and dry zones at any given time.

The unit outputs one set of clean/ dry parts every 5 minutes. The features of this carousel washer include: stainless steel construction with insulation, two tanks for wash and rinse solutions, inline micron filtration, custom fixtures on each small turntable to hold a set of transaxle parts, a steam exhaust system, a mist collection system, a sump tank and sump pump, and more.

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Camshaft and Engine Block Cleaning – Case Study 21980

camshaft crankshaft engine block conveyor washers
Conveyor Washer Engine Blocks
Conveyor Washer Engine Blocks

Background

This company is a leader in logistics and synchronous contract automotive manufacturing. They build a variety of highly complex sub-assemblies for automotive original equipment manufacturers (OEM’s). Part of their manufacturing process involves camshaft, crankshaft, and engine block cleaning.

Cleaning Challenge

Cleaning transaxle parts after machining is imperative to ensure proper product functionality. This company needed an automated cleaning system for transaxle parts that could keep up with the number of units that are manufactured and are processed through the assembly line.

Solution

The solution was two identical conveyor washers with custom fixturing. One designed for camshaft cleaning with special fixtures to hold camshafts and crankshafts and the other for engine block cleaning. These systems wash, rinse, and dry 120 parts, or sets of parts, every hour (the next step is assembly). Electronic sensors and operator flag switches allow the conveyor to index to the next part.

Each system is comprised of two 60-inch spray modules (wash and rinse) and a heated dry module with a 10HP centrifugal blower.

Other features include a parallel chain conveyor, stainless steel construction with insulation, an inline filtration system and multi-stage particle filters, a marine cleanout door, door safety switches, a steam exhaust system, an oil/ water coalescer, and a central control station with PLC.

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Battery Cell Cleaning – Case Study 22194

Conveyor Washer for Cleaning Battery Casings
Conveyor Washer for Battery Cell Cleaning
Conveyor Washer for Battery Cell Cleaning

This manufacturer produces Lithium batteries for commercial purposes. They needed an automated system to handle their battery cell cleaning process. The size of Lithium battery cells being cleaned consists of three sizes roughly the size of AA, C, and D cell batteries.

The battery cells are placed in pucks according to size. The washer was designed to receive the pucks from a Flex Link conveyor and route them as required. The puck design is identical for all three cell sizes and is tooled to present the top surface of the cells at the same height. Cells pass through a 3-chamber wash station capable of rinsing the top and bottom of the cells with pressurized nozzles located on top and bottom of the cells.

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Aircraft Wheels & Brakes Powder Coating – Case Study 20708

return conveyor washer side C-16
return conveyor washer C-16
return conveyor washer C-16

Background:

This company is a leading supplier of aircraft wheels and brakes and related hydraulic products and were looking for an automated wheel washer for their manufacturing process.

Parts Cleaning Challenge:

This plant needed to clean and coat a variety of parts prior to paint (powder coating.) The steel parts needed to be iron phosphate coated.  The aluminum parts needed a Chromium III conversion coating.

Solution/System:

The solution was two side-by-side conveyor washers.  They are identical 5-stage C-16-S2/S2/S2/S2/DH systems except they are mirror imaged.  The first system is a wheel washer and the second system is a brake washer. The stages are wash, rinse, phosphate (or conversion coat), rinse, and dry.  The parts then move around the return conveyor.

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Cosmetic Pails Drums Parts Cleaning – Case Study 21155

return conveyor barrel pail washer
Conveyor Washer for Cosmetic Drums Pails
Conveyor Washer for Cosmetic Drums Pails

Background:

At cosmetic companies, the make-up constituents are stored in plastic pails and drums. These need to be cleaned after each use. This company cleaned the containers manually using a hand-held a pressure washer. The result was a mess in more ways than one.

Parts Cleaning Challenge:

Design a conveyor washer that could clean 5 gallon pails as well as 55 gallon drums. The system had to wash and rinse the containers, fit in a really tight room and have a return conveyor so that one operator can load and unload the parts.

Solution/System:

This two (2) stage, stainless steel return conveyor washer has hinged side rails that fold down to secure the smaller pails and a CIP system for the wash and rinse tanks.

Cleaning Bearing Races for Windmills – Case Study 21486

custom turntable washer cleaning bearing races
Turntable Washer C-manifold
Turntable Washer C-manifold

Background:

This company is a leading global manufacturer of highly engineered bearings, alloy steels, and related components and assemblies.

Parts Cleaning Challenge:

They needed to remove grinding coolant, grinding wheel debris, metal chips and excess fluid from wind mill bearing races with through holes and blind holes.  The bearing races range in diameter from 65” – 140” and in weight from 1,000 lbs. – 8,000 lbs. each.

Solution/System:

This RD-14000-PCS has a 145” diameter turntable with a custom “C”-shaped manifold that swings out and lowers over the bearing race to encircle it on 3 sides.  The manifold underneath the turntable sprays the bearing races from the bottom to ensure that the parts are being sprayed with nozzles from all 4 sides for complete

Spray Washer for Large Castings – Case Study 20700

Roll-in Door 70" Diam. Turntable Washer
Roll-in Door 70" Diam. Turntable Washer
Roll-in Door 70″ Diam. Turntable Washer

Background:

This 80 year old company (same family/ 4th generation) manufacturers components for industrial hot and cold water circulation systems: pumps, valves, heat exchanges, air removal devices, etc.

Parts Cleaning Challenge:

Imported castings need to have Cosmoline removed.   Machined parts are also washed to remove chips and oils.  Much of their parts cleaning was done by hand, which they found to be inefficient.

Solution/System:

The customer bought several Better Engineering parts washers.  Most of these are turntable style spray washers including the RD-7000 unit shown in this case study. This automatic parts washer has a roll-in door, a 70” diameter turntable with 2,500 lb. holding capacity, and 60” working height.

Cleaning Automotive Components in a Work Cell – Case Study 22103

RTO Carousel Washer Automotive Parts
RTO Carousel Washer Automotive Parts

Background:

This company is a leading global manufacturer of automotive powertrain systems.

Parts Cleaning Challenge:

They needed a system to a variety of automotive parts that would fit within their existing work cell.

Solution/System:

C-5000-P-SS Carousel type cleaning system washes and dries ring gears, pinion shafts and differential housings. The system is manually loaded and unloaded from the same open, front station.

A 50” diameter turntable holds a total of 16 parts at any given time. It brings the parts through the wash and dry zones and stops each time a clean part is ready for pick-up.

Automatic Plastic Tote Washer – Case Study 21958

Tote Washer with Rails
Tote Washer with Rails
Tote Washer with Rails

Background:

This company is a global manufacturer of automotive components and systems.

Parts Cleaning Challenge:

They needed a cleaning system to clean large quantities of plastic totes used to hold and transport automotive parts throughout the manufacturing process.

Solution/System:

This conveyor tote washer has a 24″ wide belt and is designed to clean multiple sizes of plastic totes. To prevent the totes from getting blown off the conveyor belt, the system has “floating” hold-down rails that hinge up and down as the tote heights change (no manual adjustment is needed.) The C-24 has a wash module and an extra powerful heated drying section that has two (2) large centrifugal blowers to blow the water off the totes at a high rate of speed. Other features include stainless steel construction and a mist collector in front of the steam exhaust fan.

Cleaning Small Weapons Frames – Case Study 21948

Return Conveyor Washer C-24
Return Conveyor C-24
Return Conveyor C-24

Background:

This company designs, manufactures, and distributes small firearms – various models of pistols and rifles for law enforcement and the outdoor sporting industry.

Parts Cleaning Challenge:

They needed to clean chips and oils off of small weapons frames and demagnitize them during the manufacturing process.

Solution/System:

This C-24 conveyor washer is designed to clean trays of gun parts. The oval conveyor allows one operator to easily load and unload the trays from one vantage point. The sequence is as follows: 1) place a tray on gravity rollers and slide it onto the demagnetizing unit; 2) tray is then powered through the demag zone, around the turn and into the washing system; 3) trays move through four (4) clean/dry stages – wash, rinse, rinse, and dry; 4) upon exiting the conveyor, the trays come around the other turn and keep moving forward to the next available spot (zoned accumulation.) Eventually , the tray comes right back to the operator.