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!

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!

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.

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.

Automatic Gun Cleaning System – Case Study 20710

Gun Parts Washer
Gun Fixture
Gun Fixture

Background:

The military and large civilian police departments have thousands of guns at their practice ranges. These guns need to be cleaned and kept in top shape.

Parts Cleaning Challenge:

Cleaning each gun by hand is extremely time consuming and virtually impossible during busy times. Most ranges need an automatic parts washing system.

Solution/System:

An automatic gun cleaning system – a turntable style jet spray washer with wash, rinse, and dry stages. Precision fixturing allows up to 32 guns to be cleaned in a 20 minute cycle: sixteen rifles (M-4’s or M-16’s) and sixteen pistols (9 mm’s).

Drum Washer to Clean Brass Shell Casings – Case Study 21132

D-24 3-stage drum washer
Drum Washer D-14 Gas Heat
Drum Washer D-14 Gas Heat

Background:

This key corporation in the defense, aerospace, security, and outdoor
sport industries needed to clean 7.62mm brass shell casings in the
manufacturing process.

Parts Cleaning Challenge:

They were using old parts washers that no longer cleaned their parts efficiently or effectively. They needed new washers to clean the shell casings after heat treatment.

Solution/System:

Parts come to the 3-stage drum washer from an annealing oven and are washed, rinsed and dried at a rate of 30-35 lbs. per minute. The system outputs 26,000 shells per hour sending them to final machining. The drum has “scoops” to bring the fluids into the drum (there are no pumps). In the wet stages, the shells are fully immersed. The drum washer is all stainless steel.

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.