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!

Battery Cell Cleaning – Case Study 22194

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

Background

This manufacturer produces Lithium batteries and battery systems for the aviation, medical, telecom, transportation, energy, and utility industries as well as for commercial users. They needed an automated system to handle their battery cell cleaning process.

Cleaning Challenge

The batteries being cleaned vary in size and are cleaned during 3 work shifts, 7 days a week. They needed a system that would be able to adapt to clean the different sizes (roughly the size of AA, C, and D cell batteries) and also be able to handle the workload.

Solution

The solution was a custom conveyor washer designed specifically for battery cell cleaning. 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.

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

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, power transmission products, and related components and assemblies. They engineer precision bearings for large windmill turbines in the renewable energy industry and are cleaning bearing races during their manufacturing process.

Parts Cleaning Challenge:

They needed to remove grinding coolant, grinding wheel debris, metal chips, and excess fluid from windmill 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. The company needed a cleaning system that would be able to clean the blind holes along with the outer diameter of the parts as well as be able to handle the increased weight load.

Solution/System:

The solution was an RD-14000-PCS precision cleaning systemw with a 145” diameter turntable for cleaning bearing races. The system has 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 coverage.

Additional system features include two high-volume tanks for wash and rinse stages, stainless steel construction with full insulation, vertical seal-less pumps, automatic water level controls, a regenerative blower with sound shield, an oil/water coalescer, a steam exhaust system, and a central control station with PLC.

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

Spray Washer for Large Castings – Case Study 20700

Turntable Washer - Roll-in Door 70" Diam | Better Engineering
Roll-in Door 70" Diam. Turntable Washer
Roll-in Door 70″ Diam. Turntable Washer

Background:

This 80-year-old company (same family/ 4th generation) manufactures 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.

Drum Washer to Clean Multi-Tools – Case Study 22552

D-14 Drum Washer for Tooling | Better Engineering
D-14 Drum Washer for Tooling
D-14 Drum Washer for Tooling

Background:

This company is a leading manufacturer of pliers-based multi-purpose tools.

Parts Cleaning Challenge:

They needed to wash away coolant and cutting oil from knife liners on their newest product line.

Solution/System:

Production needed to accommodate running large batches of small parts (0.15 cubic inches each) for 3 shifts/day, cleaning roughly 100k parts/day; process before stamped/washed/heat treated. A two-stage (wash, dry) rotary drum washer with a 14-inch diameter helix, regenerative blower with sound cover, and oil/water coalescer met their application.

Conveyor Washer for Cleaning Compressor Parts – Case Study 22822

Conveyor Washer Compressor Parts
Conveyor Washer Compressor Parts
Conveyor Washer Compressor Parts

Background:

This company is a leading manufacturer of commercial HVAC equipment.

Parts Cleaning Challenge:

They were looking for a continuous machine to integrate with their existing in-line process and clean pallets of oily new compressor parts. The pallets are 24″ x 24″ x 24″ (with parts) and a loaded pallet can weigh up to 500 lbs.
ea.

Solution/System:

Our Cyberjet model C-24 delivered precisely the unit they needed.
The pallets automatically transition from the customer’s conveyor to the
washer conveyor on the load end, and vice versa on the unload end.
Throughput is one (1) pallet per 90 seconds. The system consists of
four (4) stages…wash, rinse, rust inhibit, dry and has a 25” belt width,
30” working height, and a 250 lb. per linear foot of conveyor weight
capacity. The conveyor has a heavy-duty drive motor and a variable
speed of 1-5 FPM .

Cleaning Perforated Sheet Metal – Case Study 22969

60" Wide Conveyor Washer for Perforated Sheet Metal
60" Wide Conveyor Washer for Perforated Sheet Metal
60″ Wide Conveyor Washer for Perforated Sheet Metal

Background:

This company is one of the largest perforated metal manufacturers in the world. 

Parts Cleaning Challenge:

They design and manufacture expanded metal, as well as perforated aluminum sheets, of all sizes. They are removing cutting oils from perforated metal sheets. The sheets vary in size with the smallest size being 24” x 24” and the largest being 60.25” W x 120” L . Throughput is 100 sheets per hour with a working envelope of 61” W x 3” H.

Solution/System:

A conveyor washer cleaning system was designed with a 60″ wide belt and wash, rinse, and heated dry cycles, as well as a blow-off between each to eliminate cross contamination and aid in the drying process.  This machine runs at 22 feet per minute!  Dynes tests were performed at different wash speeds to meet tight cleaning specifications.