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.

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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.

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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 | Better Engineering
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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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 | Better Engineering - Container Cleaning System
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.

Transmission Parts Washer – Case Study 21772

RTO Transmission Washer | Better Engineering
RTO Transmission Washer Fixture
RTO Transmission Washer Fixture

Background:

This company is a national manufacturer of automotive drivetrain components and systems.

Parts Cleaning Challenge:

They needed a compact parts cleaning system to clean transmission housings that would integrate with their existing work cell.

Solution/System:

The RTO-2000 is the perfect parts washer for a work cell. The operator loads a part, rolls the dolly into the chamber, and uses push-button controls to close the door and start the cycle. In cycle, the part rotates and water is blasted into key passageways. In just 3 minutes, the part is clean and dry, inside and out. This parts cleaning system has a 300 PSI pump, dual filtration, and a mist collection unit.

Exhaust Pipe Parts Washer – Case Study 20945

Exhaust Pipe Parts Washer | Better Engineering
Exhaust Pipe Parts Washer Fixture
Exhaust Pipe Parts Washer Fixture

Background:

This company specializes in making exhaust pipes for motorcycles. They wanted to phase out solvent tanks and use an environmentally friendly, water-based cleaning system.

Parts Cleaning Challenge:

Find a way to rack and clean a myriad of tubes (some straight and some bent) and design the washer so that the racks can be conveyed to and from the system.

Solution/System:

A PD-4000 jet-spray parts washer with powered vertical doors on the front and back sides. The operator rolls the loaded fixture into the spray cabinet, powers the doors shut, and starts the cleaning cycle. Ten minutes later, the parts are washed and dried and unloaded from the opposite doorway.

Parts Washer for Engine Blocks – Case Study 20819

Rotor Engine Block Washer | Better Engineering
Engine Piston Carousel Washer

Background:

This car manufacturing company is at the leading edge of quality. Parts are constantly pulled off the line, cleaned and measured.

Parts Cleaning Challenge:

Parts have to be clean and dry before being put into a CMM (coordinate measuring machine) unit. The engine block in question is big, heavy, and complex.

Solution/System:

This RTO-R-4000 rotor parts washer spins the engine block on a horizontal axis so the contaminants (chips and oil) and the residual water are completely flushed from the blind holes and passageways. The system has a dolly that easily rolls into the spray chamber and locks itself into the rotor.

Engine Piston Cleaning – Case Study 22177

Carousel Washer for Engine Pistons | Better Engineering
Engine Piston Carousel Washer
Engine Piston Carousel Washer

Background:

This company is a leading global automotive parts manufacturer.

Parts Cleaning Challenge:

They needed a system to clean engine pistons that would integrate with their existing work cell and robotic automation.

Solution/System:

This RTO-3000 carousel system cleans diesel engine pistons inside and out including a cavity that only has access via two small, ¼” diameter holes. Parts are robotically loaded and unloaded from the same front position. The turntable indexes every 45 seconds moving the parts through the wash, rinse, and dry zones. Features of the system include: “Zero Degree” jets to blast into the hollow cavity area, locating repeatability of +/- 0.030” for the robot, all stainless construction, regenerative blower, steam exhaust & mist collector, insulation, safety light curtains, and more.