Customer: Provider of environment, safety, and information systems for the automotive industry
Item to Clean: Aluminum brake master cylinders, 3 sizes
Contamination: Chips, dirt, dust, soluble coolant
Process Parameters: Wash, rinse, regenerative blowoff
Cleanliness Required: Cleanliness specification: < 0.2mm particle size; </= 7mg mass
Dryness Required: No visible moisture
Production Rate: 350 parts/hour
Machine Type: Aquamaster RI-5400 (Rotary Indexing)
Customer is a major global supplier of products used across several industries, including telecommunications, technology, transportation, industrial, electronic systems, construction machinery, logistics, digital media, as well as others. In the automotive sector, they provide products for environment, safety, and information systems. A sampling of these types of products includes lithium-ion batteries, electric motors, suspension systems, brake systems, vehicle navigation systems, and more. The company has locations in several countries.
The customer needed a system to clean three different sizes of aluminum brake master cylinders. The products were contaminated with chips, dirt, dust, and soluble coolant from the manufacturing process. Parts were subject to a cleanliness specification for particle size and mass, and needed to have no visual residual moisture after the cleaning process. This was a future project for the company, with an estimated production rate of 350 parts per hour.
The final design was a customized rotary indexing cleaning system, the Aquamaster RI-5400, with wash, rinse, and regenerative blowoff. This machine utilizes a 54” diameter rotary indexing turntable with custom part fixtures and part holders, which stops in nine (9) index positions for each process. These index positions include: Load/unload (at front of machine), approach, wash #1, wash #2, drain, rinse, drain, blowoff #1, and blowoff #2. Indexing is in a clockwise configuration. The machine can be run in either automatic or manual mode with the HMI interface. Using the HMI touchscreen, the operator is able to select which part type is to be cleaned for each cycle, and then program the machine for cycle times and other wash/heat settings. Pneumatic probing mechanisms were utilized for the wash and blowoff zones to accurately clean and dry blind holes and critical part areas. Manifolds can be programmed to move up and down as parts are present on the fixtures. Curtains between the wash and rinse zones were designed to prevent cross-contamination. Several optional accessories were purchased with the machine: Exhaust fan system, micro-filtration for both wash and rinse solution tanks, door safety interlock, and a light curtain for operator safety. Overall dimensions are 7’1” L x 6’2” W x 8’1” H.