Removing Hardened Resin from Ceramic Turbine Blade Castings- Case Study 22993

Parts Washer to Remove Hardened Resin
Containment Divider
Containment Divider

Background:

This company manufactures high-performance products for high-technology companies, government agencies, and academic institutions. One of the products they manufacture in particular is ceramic turbine blade castings for the aerospace industry. For this reason, lithographic etching and CNC machining are combined to produce master patterns and high-resolution lithographic inserts for these highly complex three-dimensional parts.

Parts Cleaning Challenge:

The process begins with 3D printing the model in a wax-like resin. This resin hardens on the molds and is difficult to remove. As a result, the challenge was to remove hardened resin from the ceramic turbine blade molds.

Solution/System:

In this case, the solution was a Cyberjet conveyor washer with a 14” wide belt with a recirculated spray wash and two recirculated spray rinse zones. A temperature of at least 165° F has to be maintained, the wash tanks and rinse tanks were increased to 225 gallons each, and the heater elements increased to 27 kW in order to remove the hardened resin. The throughput is one fixture of parts every 8 minutes, and pusher bars were affixed to the belt to help maintain a specific distance in the center of each module.

In addition, a wax removal basket and containment divider was designed for every stage. The system also included marine cleanout doors for both the wash and rinse stages for easy maintenance. A steam containment door was installed at the exit side of the machine instead of spray curtains to limit the amount of time steam can escape from the unit. Altogether, this type of system worked well as this was an indexing unit, loaded and unloaded robotically. The system also featured:

  • Allen Bradley CompactLogix PLC and Panelview
  • variable frequency drive controls
  • water level controls
  • locking lid safety switches
  • safety guarding on the load and unload ends to cover bearings and sprockets
  • electronic pressure switches
  • in-line bag filters
  • insulation for the entire system

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

Aircraft Wheels & Brakes Powder Coating – Case Study 20708

Return conveyor aircraft wheel washer C-16 | Better Engineering - Conveyor Washers
Return conveyor aircraft wheel washer C-16 front
Return conveyor aircraft wheel washer C-16 front

Background:

This company is the global leader in motion and control technologies for industrial and aerospace markets. They are a leading supplier of aircraft wheels and brakes and related hydraulic products. They were looking for an automated aircraft wheel washer and brake washer for their manufacturing process.

Parts Cleaning Challenge:

This plant needed to clean and powder coat a variety of parts, including aircraft wheels and brakes, prior to painting to help ensure the durability of the parts. The steel parts needed to be iron phosphate coated and 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 an aircraft wheel washer and the second system is a brake washer. The stages are wash, rinse, phosphate (or conversion coat), rinse, and dry. The dry stage is powered by a 5HP regenerative blower.  The parts then move around the powered return conveyor for easy unloading.

Additional system features include low water shutoff and automatic fill, an oil skimmer, inline micron filtration for the wash tank, a steam exhaust system, lid safety switches, marine cleanout doors for easy cleaning access to the tanks, a sound shield for the regenerative blower, and a central control station.

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

Parts Washing System for Helicopter Gear Boxes – Case Study 21319

Rotor Parts Washer for Helicopter Gear Boxes | Better Engineering
Rotor Parts Washing System for Helicopter Gear Boxes
Rotor Parts Washing System for Helicopter Gear Boxes

Background:

This company manufactures a wide range of civil and military helicopters.

Parts Cleaning Challenge:

They needed to clean gear boxes to the most stringent cleaning requirements.

Solution/System:

The solution was a return-to-operator (RTO) parts washing system. This RTO-R-6000-PCS washer rotates the parts around a horizontal axis as they are being sprayed to flush out complex passages.  A dolly transports the parts in and out of the spray chamber.  This system has four tanks and a five stage cleaning cycle: a wash stage followed by three rinse stages and a dry stage.  The company has reported to us that before this machine was implemented into their cleaning program they only had a 20% parts approval rating.  After only a few months implementation, they are on track to reach an 85% approval rating with projected subsequent further improvement ratings.

Parts Washer for Robotic Work Cell – Case Study 22090

Robotically Loaded Dual Door Parts Washer | Better Engineering
Dual Vertical Door Parts Washer
Dual Vertical Door Parts Washer
Background:

This company is a leading, global aerospace manufacturer for both commercial and defense industries.

Parts Cleaning Challenge:

They needed a parts cleaning system that would integrate with their existing robotic work cell system.

Solution/System:

This RTO-2000 industrial parts washer is a two (2) chamber jet washer for a robotic work cell… one robot loads and unloads the washing system as well as other machining centers. The two cleaning chambers are segregated so that each works independently of the other. Parts being cleaned are integrated fan blade components for the aerospace industry.

Automatic valves for the water and air pathways make this possible. The cleaning cycle has 4 stages: wash, rinse, fresh rinse, and dry. Features include: 2 chambers/2 turntables, automatic roll-out dollies, three heated tanks, Ethernet communications, and more.

Parts Washer for Jet Engine Overhaul – Case Study 20901

turntable washer for aerospace cleaning
Twin Precision Cleaning Systems for Aerospace Parts
Twin Precision Cleaning Systems for Aerospace Parts
Background:

The customer is a major re-builder of jet engines. They work in conjunction with the leading jet engine manufacturers.

Parts Cleaning Challenge:

The customer needed to replace an older parts washer that could not achieve the required cleanliness levels. The major problem was rinse water contamination. The parts held a lot of wash water which overwhelmed the small rinse tank.

Solution/System:

Twin model RD-6000-ULT systems designed for final, precision cleaning of critical jet engine components. These parts cleaning systems have a roll-in door and a spray/dry manifold that automatically lowers into the parts. Both the interior and exterior surfaces are directly impacted as the machines cycle through the following stages… wash, rinse, fresh rinse, and dry. Other features include part collision sensor for the ID manifold, all stainless steel construction, steam heat for the tanks, vacuum system, viewing window, mist collector, 10″ HMI screen, etc. Each machine features a two(2) tank system with a 60″ diameter turntable and 60″ work height.