Automotive Crankshaft Multi-Station Final Cleaning System

The Big Bird Industrial Crankshaft Multi-Station Final Cleaning System is developed for final cleaning of automotive crankshafts after machining and oil-based polishing operations. The system removes cutting fluids, metal chips, oil contaminants, and particulate residues from oil galleries, threaded holes, and all external surfaces before assembly.

The equipment is provided as a turnkey solution including design, manufacturing, installation, and commissioning.

Workpiece Applications

The system accommodates automotive crankshaft components:

All workpieces are automotive crankshafts for engine manufacturing applications. The system is designed with manual changeover capability for additional crankshaft variants through fixture replacement, program adjustment, and robot trajectory modification.

Automatic Mixed-Model Production

The system supports automatic mixed-model production with:

Automatic Loading

• Gantry robot automatically places the workpiece onto V-block locating seats at the loading station

• Slide drive mechanism transfers the workpiece to the robot pick-up position

• Center hole blow-off before robot gripping

• Workpiece identification system (switch-based) for existing variants

• Error-proofing: axial detection, radial detection, and large/small end orientation detection

• Safety guard with electronic interlock

Robot System

• ABB IRB6700-200/2.6 6-axis robot

• IP67 protection

• 100 kg maximum payload

• Robot gripper features self-locking function (workpiece cannot fall on power/air loss)

• Manual gripper change for different workpiece variants

Manual Unloading

• Operator removes workpiece at the unloading station

• Safety light curtain for operator protection

• Workpiece locating mechanism for laser marking (laser marker provided by customer)

Multi-Stage Cleaning Process

The system combines multiple cleaning technologies in an 8-stage automated sequence:

Stage 1: Loading (1ST)

The gantry robot automatically places the workpiece onto V-block locating seats at the loading station. The slide drive mechanism transfers the workpiece to the robot pick-up position. The robot performs center hole blow-off before gripping, then transfers the workpiece into the cleaning chamber.

Manual changeover of locating blocks is required when switching workpiece variants. The station features workpiece identification (switch-based), error-proofing (axial detection, radial detection, orientation detection), and safety guard with electronic interlock.

Stage 2: Ultrasonic & Spray Cleaning (2ST) — 0.5 MPa

The robot transfers the workpiece to the ultrasonic cleaning station pallet. The pallet lowers, submerging the workpiece in the cleaning tank which has been pre-filled with cleaning fluid. Ultrasonic cleaning (25 kHz) removes contaminants from all surfaces and internal passages.

After ultrasonic cleaning, spray nozzles on both sides perform spray cleaning of the workpiece surface. After cleaning, the lifting mechanism raises the workpiece, and the robot transfers it to the next station.

Stage 3: High-Pressure Fixed-Point Cleaning (3ST) — 15–20 MPa (Max 28 MPa)

The robot transfers the workpiece to the high-pressure cleaning station pallet. The XYZ three-axis module positions nozzles for high-pressure cleaning of center holes at both ends.

After center hole cleaning, the servo motor drives clamping arms to clamp the workpiece via centers at both ends, with locating pins engaging the locating pin holes. The pallet lowers, and the clamping mechanism rotates the workpiece to the specified angle.

The XYZ three-axis module performs fixed-point and scanning high-pressure cleaning of workpiece surfaces and oil galleries. After cleaning, blow-off nozzles dry the workpiece. The robot then transfers the workpiece to the next station.

The spindle features automatic nozzle change with three nozzle types: straight nozzles, fan nozzles, and angled nozzles, with corresponding nozzle holders.

Stage 4: Spray Rinsing (4ST)

The robot transfers the workpiece to the rinsing station pallet. The servo motor drives clamping arms to clamp the workpiece via centers at both ends, with locating pins engaging the locating pin holes. The pallet lowers, and the clamping mechanism rotates the workpiece to the specified angle.

The XYZ three-axis module performs fixed-point and scanning rinsing of workpiece surfaces and oil galleries. After rinsing, blow-off nozzles dry the workpiece. The robot then transfers the workpiece to the next station.

The spindle features automatic nozzle change with three nozzle types: straight nozzles, fan nozzles, and angled nozzles.

Stage 5: Transfer Point (5ST)

The robot places the cleaned workpiece onto the transfer pallet. The chain conveyor system transports the workpiece to the next station.

Stage 6: Hot Air Drying (6ST)

The workpiece and pallet are conveyed to the hot air drying station. Positioning cylinders lock the pallet in position. Cylinders drive air knives up and down across the crankshaft for thorough drying.

After drying, all cylinders return to their original positions, and the workpiece is conveyed to the next station.

Stage 7: Vacuum Drying (7ST)

The workpiece and pallet are conveyed to the vacuum drying station. Positioning cylinders lock the pallet in position. The upper movable vacuum hood descends to form a sealed chamber with the pallet. The vacuum pump evacuates the chamber and maintains vacuum for a set period, removing residual moisture from all surfaces and internal passages.

After vacuum drying, all cylinders return to their original positions, and the workpiece is conveyed to the next station.

Stage 8: Unloading (8ST)

The workpiece and pallet are conveyed to the unloading position. The operator removes the workpiece. Manual changeover of pallet locating blocks is required when switching workpiece variants.

A fan provides air blow-off (with adjustable temperature heating) on the workpiece surface. A safety light curtain protects the operator. A workpiece locating mechanism positions the workpiece for laser marking (laser marker provided by customer).

High-Pressure Cleaning Technology

The system features high-pressure cleaning with exceptional capability:

Technical Cleanliness Control

For automotive engine manufacturing, cleanliness of crankshaft oil galleries and surfaces directly affects engine reliability and performance.

The system is designed to meet strict cleanliness requirements:

Advanced Filtration Management (All Filters with Magnetic Rods)

The system employs a multi-stage filtration system with magnetic rods in all bag filters for powder particle removal:

Filtration Features:

• All bag filters equipped with magnetic rods for powder particle removal

• Magnetic grids at machine return flow points

• Blockage alarm with manual switch/change without production interruption

• Non-stop filter change capability

Intelligent Manufacturing Integration

The system supports Industry 4.0 requirements through comprehensive data connectivity:

MES Communication

• Ethernet RJ-45 interface

• Open data protocol for MES integration

• Production data upload and download capability

Operator Interface

• Siemens HMI with color display

• Equipment status and fault display

• Audible and visual alarms (Red/Yellow/Green)

• PLC program with three-level password protection

• Daily maintenance reminders with escalation (operator cannot clear, manager confirmation required)

Control System

• Siemens S7-1500 PLC

• PROFINET bus communication with VFDs and field I/O

• Electrical component protection rating: IP54

• Power meter configuration for energy monitoring

Application Case

Complete Cleaning Solution

Big Bird Industrial provides comprehensive engineering solutions including:

Process Development

• Component analysis for automotive crankshafts

• Cleaning process design for final cleaning applications

• Cleanliness requirement evaluation

Equipment Integration

• Multi-station cleaning systems

• Ultrasonic cleaning technology (25 kHz)

• High-pressure cleaning systems (15–20 MPa, max 28 MPa)

• Vacuum drying systems

• Conveyor and pallet handling systems

• Automatic nozzle change systems

Smart Manufacturing Connection

• MES interface

• Production data acquisition

• Energy monitoring

Why Choose Big Bird Industrial

Automotive Crankshaft Experience

Big Bird Industrial specializes in precision cleaning solutions for automotive powertrain components, with proven experience in crankshaft final cleaning for major automotive engine manufacturers.

Multi-Station Cleaning Technology

The system integrates ultrasonic cleaning, spray cleaning, high-pressure fixed-point cleaning (15–20 MPa, max 28 MPa), rinsing, hot air drying, and vacuum drying in a single, compact 8-station configuration for comprehensive contaminant removal.

High-Pressure Cleaning with Automatic Nozzle Change

The system features XYZ three-axis high-pressure cleaning with automatic nozzle change capability (straight, fan, and angled nozzles) for precise cleaning of all oil galleries, center holes, and surfaces.

System-Level Engineering Capability

The company provides complete solutions from cleaning process development to production integration, including ultrasonic cleaning, high-pressure cleaning, vacuum drying, and MES connectivity.

Customized Non-Standard Engineering

Each component and production line has unique requirements. Big Bird Industrial provides customized engineering solutions based on:

• Component structure and material analysis

• Cleaning process development

• Customized fixture and automation design

• Factory layout and production flow integration

FAQ

What components does this cleaning system process?

This system is designed for automotive crankshafts up to 800 mm in length, Φ250 mm swing diameter, and 60 kg in weight for engine manufacturing.

What cleaning pressure is available?

The system delivers high-pressure cleaning at 15–20 MPa (max adjustable 28 MPa) with intelligent VFD control, plus spray cleaning at 0.5 MPa.

What cleaning technologies are integrated?

The system integrates ultrasonic cleaning (25 kHz), spray cleaning, high-pressure fixed-point cleaning, spray rinsing, hot air drying, and vacuum drying in an 8-station configuration.

What contaminants can be removed?

It removes cutting fluids, metal chips, oil contaminants, and particulate residues from oil galleries, center holes, and all external surfaces.

What cleanliness levels can be achieved?

Total residual contamination ≤10 mg; oil gallery contamination ≤3 mg; maximum particle size ≤0.6 mm; with strict particle count limits per size range.

Does it support automated production integration?

Yes. The system features automatic loading via gantry robot interface, automatic workpiece identification, error-proofing, and MES communication capability.

What is the typical cycle time?

The system delivers ≤180 seconds per piece (including robot loading/unloading), with cycle time customizable per production line requirements.

Crankshaft Final Cleaning in Automotive Engine Manufacturing

Crankshaft final cleaning is a critical process between machining and assembly in automotive engine manufacturing. Crankshafts with complex oil galleries, center holes, and precision surfaces require advanced cleaning technologies to remove cutting fluids, metal chips, oil contaminants, and particulate residues. Ultrasonic cleaning reaches internal passages that conventional spray cleaning cannot access, while high-pressure cleaning ensures thorough removal of stubborn contaminants from all surfaces.

Ultrasonic & High-Pressure Cleaning for Crankshaft Components

Automotive crankshafts present unique cleaning challenges due to their complex geometries, oil galleries, and precision surfaces. Ultrasonic cleaning effectively removes contaminants from internal passages and blind holes, while high-pressure cleaning (15–20 MPa, max 28 MPa) provides the cleaning power needed for stubborn residues. Multi-stage cleaning sequences with integrated drying ensure complete contaminant removal and corrosion protection.

Vacuum Drying Technology for Component Protection

Vacuum drying technology ensures complete moisture removal from crankshaft surfaces and internal passages without thermal stress or water spots. The reduced pressure environment lowers the saturated steam temperature, evaporating residual moisture efficiently. Combined with hot air drying, vacuum drying eliminates the risk of corrosion and water spots on precision surfaces.

Magnetic Filtration Technology for Powder Particle Removal

Effective filtration is essential for maintaining cleaning quality in crankshaft cleaning. Magnetic separators and bag filters with magnetic rods effectively remove ferrous powder particles from cleaning fluid, protecting pumps and nozzles while ensuring consistent cleaning results. Non-stop filter change capability with blockage alarms ensures continuous operation without production interruptions.

Technical Specifications