Alliance Manufacturing developed an automated aluminum case cover cleaning system for a large manufacturer of commercial engines, generators, and other power products. The system was designed to remove machining coolant and chips from aluminum engine case covers while providing targeted cleaning and complete drying of part features and passageways.
The Aquamaster RI-6000 rotary indexing parts washer was configured to process one part per minute while maintaining a single operator load and unload location.
Customer Background
The customer is a large manufacturer of power products, including commercial engines and generators used across multiple industries.
Manufacturing aluminum engine components can leave coolant, chips, and other machining residues on surfaces and within part features. These contaminants need to be removed before the component moves to subsequent manufacturing or assembly operations.
Challenge
Cleaning Aluminum Engine Case Covers
The customer needed an automated system for aluminum case cover cleaning that could operate from a single load and unload location.
The geometry of the case covers presented an additional challenge. Coolant and aluminum chips could remain on surfaces and within specific features and passageways, making targeted cleaning important.
Drying was also a critical requirement. Each case cover needed to exit the cleaning cycle 100% dry, including areas where residual water could become trapped.
The cleaning system therefore needed to combine effective chip and coolant removal with targeted drying while maintaining the required production rate of one part per minute.
Solution
Rotary Indexing Aluminum Component Cleaning
Alliance provided an Aquamaster RI-6000 rotary indexing parts washer with a unique servo-driven turntable. The turntable rotates both clockwise and counterclockwise during the same cycle to move parts through the required process zones while maintaining a single operator loading and unloading position.
Each aluminum case cover is placed on a specially designed fixture to maintain proper positioning throughout the cleaning cycle.
The wash zone combines general spray coverage with targeted nozzles positioned to reach specific part features and passageways. This approach helps remove machining coolant and chips from areas that may be difficult to clean with general spray coverage alone.
The blowoff zone also incorporates general and targeted nozzles to remove residual moisture and meet the customer’s 100% dryness requirement.
Automated Indexing and Part Handling
The rotary indexing design provides a controlled and repeatable aluminum component cleaning process while supporting the required production rate.
The system includes indicated loading and unloading along with part tracking through the HMI screen. Operators can monitor part movement through the cleaning process while dedicated fixtures maintain consistent positioning.
The machine is designed for manual loading and unloading and incorporates a light curtain to help protect the operator during production.
Cleaning Method
Aqueous spray cleaning was selected based on the size and geometry of the aluminum case covers and the need to remove coolant and chips from specific features and passageways.
Combining general spray coverage with strategically positioned nozzles allows the cleaning process to address both exposed surfaces and more difficult-to-reach areas. Targeted compressed-air blowoff then removes retained moisture from those same features.
This combination of washing, fixturing, automated indexing, and targeted drying provides a repeatable process for cleaning machined aluminum engine components.
Application Result
The customized Aquamaster RI-6000 provides an automated aluminum case cover cleaning process capable of washing and completely drying one engine case cover per minute.
By designing the fixtures, spray nozzles, blowoff system, and indexing sequence around the component geometry, Alliance provided a system that removes coolant and chips while addressing difficult-to-reach features and passageways.
The application demonstrates how automated parts washing can be configured for aluminum component cleaning when part geometry, contamination, drying, production rate, and operator handling must all be considered.
Frequently Asked Questions
Need an Aluminum Component Cleaning System?
Alliance Manufacturing engineers aqueous parts washing systems around component geometry, contamination, cleanliness, drying, and production requirements.
