Automotive Cylinder Head Intermediate Cleaning System

The Big Bird Industrial Cylinder Head Intermediate Cleaning System is developed for post-machining cleaning of cylinder heads used in heavy-duty diesel engine manufacturing. The system removes machining residues before subsequent processes and supports full automatic mixed-model production without manual changeover.

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

Workpiece Applications

The system accommodates multiple cylinder head variants for heavy-duty diesel engine manufacturing:

All workpieces are cylinder head sub-assemblies for heavy-duty diesel engine applications. The system supports full automatic mixed-model production without manual changeover.

Automatic Mixed-Model Production

The system supports fully automatic mixed-model production with the following capabilities:

QR Code Recognition

QR code scanning devices automatically read workpiece identification upon loading. The system selects the appropriate cleaning program based on the QR code information. Storage capacity supports up to 256 part number variants. An additional automatic barcode printer (2 units) is configured for production traceability.

Dual-Workpiece Handling

The system features two 6-axis robots capable of handling two cylinder heads simultaneously, doubling production efficiency with a cycle time of 76 seconds per two pieces (38 seconds per piece).

Automatic Model Changeover

Fixtures, nozzles, and positioning components are designed to accommodate all cylinder head variants without manual intervention. Fixture locating surfaces feature automatic cleaning to prevent chip-induced workpiece damage.

MES Communication

The system interfaces with MES for production tracking, data acquisition, and status updates per the automotive OEM's general technical requirements.

Multi-Stage Cleaning Process

The system combines multiple cleaning technologies in a 9-stage automated sequence with dual-workpiece handling:

Stage 1: Loading (1ST)

The upstream conveyor transfers the workpiece to the cleaning system loading roller conveyor. The conveyor transports the workpiece to the machine入口. A QR code scanner (COGNEX) identifies the workpiece model.

The入口 features two workpiece positioning points. A lift-and-rotate mechanism lifts and rotates two workpieces 180°, enabling the robot to grip both cylinder heads simultaneously into the cleaning chamber. The loading conveyor features PZR roller design.

An operator inspection station is provided at the loading position.

Stage 2: Turbulent Cleaning (2ST) — 1.5 MPa

Robot #1 grips two workpieces and transfers them into the turbulent cleaning tank, which has been pre-filled with cleaning fluid. The robot flexibly changes workpiece orientation while surrounding nozzles direct turbulent flow to clean all surfaces.

Stage 3: Water Jacket Plug Cleaning (3ST) — 1.5 MPa

After turbulent cleaning, the tank drain valve opens for rapid drainage. The robot positions the workpieces at large-diameter nozzles for water jacket plug cleaning, ensuring thorough cleaning of cooling passages.

Stage 4: Fixed-Point Cleaning (4ST) — 1.5 MPa

After water jacket plug cleaning, the workpieces are positioned at fixed-point nozzle panels. Each nozzle is precisely aligned with corresponding holes on the cylinder head, ensuring all passages receive targeted cleaning. The robot changes workpiece orientation to align each surface with corresponding nozzle panels, and the cleaning pump continues refilling the turbulent tank for the next cycle.

Stage 5: Water Jacket Precision Cleaning (5ST) — 0.6 MPa

Robot #1 places two workpieces simultaneously onto the positioning pallets at this station. Cylinders extend nozzles to perform water jacket plug cleaning while simultaneously conducting precision cleaning of the overall workpiece. This station features two positions to extend precision cleaning time. Robot #1 places workpieces in one position while Robot #2 retrieves previously cleaned workpieces from the other position. This station features independent water tank, pump, and filtration system.

Stage 6: Fixed-Point Blow-Drying (6ST) — 0.2–0.4 MPa

Robot #2 grips the workpieces and moves them to the blow-drying station. During transfer, the robot changes workpiece orientation for tilt-drainage. The robot then positions the workpieces at fixed nozzle boxes for targeted blow-drying of all holes and passages. Each surface has corresponding nozzle panels. After fixed-point blow-drying, the robot performs scanning blow-drying across workpiece surfaces. After drying, Robot #2 places the workpieces onto the gravity roller conveyor at the machine outlet, and transfer bars simultaneously advance both workpieces to the next station.

Stage 7: Secondary Blow-Drying (7ST)

Transfer bars convey two workpieces into the secondary blow-drying chamber with gravity roller conveyor. Upper cylinders extend nozzle boxes for fixed-point scanning blow-drying of the overall workpiece. After secondary blow-drying, transfer bars simultaneously advance both workpieces to the next station.

Stage 8: Vacuum Drying (8ST)

Transfer bars convey two workpieces into the vacuum chamber with gravity roller conveyor. The upper movable hood closes with the bottom fixed hood to form a sealed chamber. The vacuum pump evacuates the chamber, lowering the saturated steam temperature to evaporate residual moisture from component surfaces. After vacuum drying, the vacuum chamber vents, the hood returns, and transfer bars advance both workpieces to the next station.

Stage 9: Unloading (9ST)

Transfer bars convey two workpieces to the unloading station gravity roller conveyor. Upon arrival, the gravity conveyor lowers, transferring workpieces to the motor-driven conveyor for individual transfer to downstream equipment. An operator inspection station is provided. The unloading conveyor features PZR roller design with workpiece presence detection.

Technical Cleanliness Control

For heavy-duty diesel engine manufacturing, cleanliness of internal passages directly affects engine reliability and performance.

The system is designed to meet strict cleanliness requirements for each cylinder head passage:

Advanced Filtration Management

The system employs a three-stage filtration system for the cleaning circuit and a two-stage filtration system for the precision cleaning circuit:

Cleaning Circuit Filtration (Three-Stage):

• Stage 1: Drum filter — 1,500 L/min, 50 μm, stainless steel mesh, with auto-backflush and chip cart

• Stage 2: Automatic back-flush filter — 30 μm, with back-flush magnetic separator

• Stage 3: Bag filter — 900 L/min, 10 μm, non-woven fabric (1 standby + 1 active), with blockage alarm

Precision Cleaning Circuit Filtration (Two-Stage):

• Stage 1: Basket filter — 300 L/min, 40 mesh, nylon mesh, with blockage alarm

• Stage 2: Bag filter — 300 L/min, 10 μm, non-woven fabric (1 standby + 2 active), with blockage alarm

Filtration Features:

• All filters feature blockage alarms displayed on HMI

• Filter replacement does not affect normal equipment operation

• Automatic separation of cleaning fluid from chips and waste residue

• Mobile chip cart for easy disposal

Robot System

The system utilizes two FANUC robots for efficient dual-workpiece handling:

Intelligent Manufacturing Integration

The system supports Industry 4.0 requirements through comprehensive data connectivity:

MES Communication

• OPC UA protocol support

• QR code-based workpiece tracking

• Production status updates

Data Acquisition

• Equipment fault monitoring (time, frequency)

• Production count and cycle time recording

• Equipment uptime tracking

• Power consumption monitoring (SIEMENS smart meter)

Operator Interface

• 15" TFT color touch screen (minimum)

• Chinese language interface

• Workpiece information display

• Cleaning program selection

• Cleaning progress monitoring

• Temperature and pressure display

• Fault diagnosis and alarm display with troubleshooting guidance

• Tank liquid level monitoring and alarm

Smart Features

• Automatic lubrication at scheduled intervals

• Automatic maintenance reminders on HMI

• Remote diagnostic capability

Application Case

Complete Cleaning Solution

Big Bird Industrial provides comprehensive engineering solutions including:

Process Development

• Component analysis for cylinder heads

• Cleaning process design

• Cleanliness requirement evaluation

Equipment Integration

• Robotic cleaning systems with dual-workpiece handling

• Turbulent cleaning technology

• Water jacket plug cleaning systems

• High-pressure fixed-point cleaning

• Vacuum drying technology

• Multi-stage filtration management

• Automated material handling

Smart Manufacturing Connection

• MES interface (OPC UA)

• QR code traceability

• Production data acquisition

Why Choose Big Bird Industrial

Heavy-Duty Engine Component Experience

Big Bird Industrial specializes in precision cleaning solutions for automotive powertrain components, with proven experience in cylinder head cleaning for heavy-duty diesel engine applications.

Dual-Workpiece Robotic Handling

The system features two FANUC robots capable of handling two cylinder heads simultaneously, delivering rapid cycle times of 38 seconds per piece with OEE ≥95% for high-volume production.

Multi-Stage Cleaning Technology

The system combines turbulent cleaning, water jacket plug cleaning, fixed-point cleaning, water jacket precision cleaning, blow-drying, and vacuum drying for comprehensive contaminant removal from complex cylinder head geometries.

System-Level Engineering Capability

The company provides complete solutions from cleaning process development to production integration, including robotic handling, 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

The company's non-standard engineering capability allows each cleaning system to be tailored to specific component geometry, cycle time requirements, cleanliness standards, and automation level.

Compliance with Standards

All equipment complies with ISO 13849, IEC 62061 (SIL3), GB 5226.1, and applicable Chinese and international safety standards. Pressure vessels are certified by third-party inspection authorities.

FAQ

What components does this cleaning system process?

This system is designed for cylinder head sub-assemblies for heavy-duty diesel engine models.

What contaminants can be removed?

It removes metal chips, machining particles, cutting fluid residues, and internal contamination from oil galleries, fuel passages, intake/exhaust ports, and cooling jackets.

Can it clean water jackets and oil galleries?

Yes. The system combines turbulent cleaning, water jacket plug cleaning, and fixed-point cleaning to reach all internal passages including rocker arm oil galleries, fuel return galleries, oil return galleries, intake/exhaust ports, and cooling water jackets.

What cleanliness levels can be achieved?

Rocker arm oil gallery ≤0.4 mg; fuel return gallery ≤1.5 mg; oil return gallery ≤7.3 mg; intake/exhaust ports ≤14.5 mg; cooling jacket ≤56 mg.

Does it support automated mixed-model production?

Yes. QR code recognition selects the appropriate cleaning program. Fixtures and nozzles are designed for all variants. No manual changeover is required.

What is the cycle time?

The system delivers ≤38 seconds per piece (76s/2 pieces), supporting production of ≥719 qualified pieces per 8-hour shift.

Does it support MES integration?

Yes. OPC UA communication, QR code traceability, production data acquisition, and MES interface are fully supported.

Cylinder Head Intermediate Cleaning in Heavy-Duty Diesel Engine Manufacturing

Cylinder head intermediate cleaning is a critical process between machining and subsequent operations in heavy-duty diesel engine manufacturing. The complex geometry of cylinder heads—including multiple oil galleries, fuel passages, intake/exhaust ports, and cooling water jackets—requires advanced cleaning technologies to remove machining residues, metal chips, and cutting fluid contaminants. Modern engine manufacturers demand strict cleanliness levels for internal passages to ensure reliable engine performance, fuel efficiency, and emissions compliance.

Turbulent Cleaning for Complex Cylinder Head Geometries

Turbulent cleaning provides superior contaminant removal for complex cylinder head geometries. By immersing the workpiece in heated cleaning fluid and creating turbulent flow, the technology reaches internal passages and blind holes that conventional spray cleaning cannot access. Combined with water jacket plug cleaning and fixed-point cleaning, turbulent cleaning ensures thorough removal of machining residues from all surfaces and internal passages.

Robotic Dual-Workpiece Handling for High-Volume Production

Robotic dual-workpiece handling systems enable high-volume production with rapid cycle times. Two robots handling two workpieces simultaneously achieve cycle times of 38 seconds per piece while maintaining consistent cleaning quality. Combined with QR code recognition and automatic model changeover, these systems support fully automatic mixed-model production without manual intervention.

Filtration Technology in Cylinder Head Cleaning

Effective filtration systems are fundamental to maintaining consistent cleaning quality in cylinder head cleaning. Three-stage filtration configurations—combining drum filters, automatic back-flush filters, and bag filters—enable continuous operation with non-stop filter changes. Filtration accuracy down to 10 μm ensures cleaning fluid quality is maintained, reducing recontamination risks and extending fluid life.

Technical Specifications