Customer: Manufacturer of aircraft engines
Item to Clean: Crankshafts
Contamination: Coolant, oil, and chips
Process Parameters: Wash, rinse, heated blowoff
Cleanliness Required: Under 3 milligrams/liter (external) and 5 milligrams/liter (internal passages). Particle size not to exceed 150×100 µ with maximum particle count not to exceed 50.
Dryness Required: 100% dry
Production Rate: Not specified
Machine Type: Aquamaster CI-4200E (Conveyorized Indexing)
Customer is a leading manufacturer of piston aircraft engines. In the company’s early years, it was a general manufacturing plant and then began producing engines for automobiles. Its focus eventually shifted to aviation. They specialize in the engineering, manufacturing, assembly, testing, and support of their aircraft engines.
Customer was seeking a solution for cleaning crankshafts contaminated with machine coolant, oil and chips. Upon exiting, the crankshafts had to be 100% dry and meet strict cleanliness guidelines (see above). Surfaces within the holes, blind and through holes needed to be as clean and dry as any outside surface. A production rate of 16 crankshafts per hour was required.
Alliance provided a three stage, Aquamaster CI-4200E indexing conveyorized crankshaft cleaning system. The wash and rinse modules have a 250 gallon tank capacity (nominal), 3-position solution level control and pneumatic spray manifolds. A heated blowoff module equipped with high-velocity air knives located above and below the conveyor provide general drying. Strategically located compressed air nozzles are timed to blast moisture from oil holes when stopped in an indexed position. A pneumatic blowoff manifold lowers into position for drying moisture in horizontal holes and hard-to-reach critical areas.
The conveyor is an indexing system with part fixtures equipped for manual loading and unloading of a variety of crankshafts. Index cycle time can be programmed based on production time. A laser sensor helps determine the correct orientation when loading parts. Alliance’s patented “FulAcess” lift-off canopy segments provide easy access to the interior, and are equipped with sensors to disable the machine if removed during operation. A customer-specified mist collection system was incorporated into the design. 80/20 mesh guarding and light curtains were included at the load end of the machine for operator safety.
Overall dimensions are 24’0” long x 8’0” wide x 4’9” high with a conveyor capacity of 42” wide x 9” high product opening.