Commercial Vehicle Transmission Retarder Stator/Rotor High-Pressure Cleaning System

The Big Bird Industrial Stator/Rotor High-Pressure Cleaning System is developed for post-machining cleaning of stator and rotor components used in commercial vehicle transmission retarder systems. The system removes machining chips, graphite particles, iron powder, and cutting fluid residues before final assembly and supports mixed-model production for multiple workpiece variants.

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

Workpiece Applications

The system accommodates multiple stator/rotor variants for transmission retarder applications:

All workpieces are transmission retarder stator and rotor components for heavy-duty commercial vehicle applications. The system is designed to accommodate parts within 700 × 600 × 600 mm dimensions and up to 80 kg weight.

Automatic Mixed-Model Production

The system supports automatic mixed-model production with:

QR Code Recognition

A COGNEX QR code scanning device automatically reads workpiece identification upon loading. The scanner is horizontally adjustable for flexible positioning.

Vision Inspection System

A COGNEX vision system with camera inspection confirms workpiece type and orientation upon loading, ensuring correct program selection.

Manual Pallet Changeover

Two pallet types accommodate all 12 workpiece variants. Changeover is performed manually between part families (stator vs. rotor) using a quick-change pallet system.

Error-Proofing

Workpiece presence detection and orientation verification prevent loading errors and ensure process integrity.

Multi-Stage Cleaning Process

The system combines multiple cleaning technologies in a 6-stage automated sequence:

Stage 1: Loading (1ST)

The operator places the workpiece onto the locating pallet on the loading roller conveyor. The conveyor transports the workpiece to the robot pick-up position. The robot grips the workpiece and transfers it into the cleaning chamber.

After the robot removes the workpiece, the empty pallet is returned to the loading position, ready for the next workpiece. This station features workpiece orientation detection, presence detection, QR code scanning, and vision inspection for part identification. Two pallet types accommodate all workpieces with manual changeover between stator and rotor variants.

Stage 2: Turbulent & Fixed-Point Cleaning (2ST) — 1.0 MPa

The 6-axis robot holds the workpiece and transfers it 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.

After turbulent cleaning, the drain valve opens to rapidly drain the tank (drain time ≤5 seconds). The robot positions the workpiece at fixed nozzle boxes arranged according to the workpiece hole patterns. The robot changes workpiece orientation to align each surface with corresponding nozzle panels, ensuring all holes and internal cavities receive targeted cleaning.

Two nozzle box panels accommodate large and small workpiece families, with manual changeover between them. After cleaning, the robot transfers the workpiece to the next station. The cleaning pump continues filling the turbulent tank so it is ready for the next workpiece.

Stage 3: High-Pressure Cleaning (3ST) — ≥35 MPa (Max Adjustable 50 MPa)

The robot transfers the workpiece to the high-pressure cleaning station. The robot changes workpiece orientation to align with high-pressure fixed-point nozzles, performing high-pressure cleaning on critical areas including blind holes and internal cavities.

This station features linear nozzles and 90° angle nozzles for comprehensive coverage. Additional high-pressure rotating nozzles (spray curtain diameter ≥60 mm) provide scanning cleaning across workpiece surfaces.

After high-pressure cleaning, the robot transfers the workpiece to the next station with tilt-drainage during transfer.

Stage 4: Comprehensive Rinsing (4ST) — Spray Rinsing + Immersion Turbulent Rinsing + High-Efficiency Drying

The robot places the workpiece onto the positioning pallet within this station. Clamping mechanisms secure the workpiece in position.

A movable water tank extends to enclose the workpiece with the fixed cleaning tank. Fixed-point nozzles perform spray rinsing on the workpiece. Simultaneously, water gradually fills the tank, immersing the workpiece in cleaning fluid and creating turbulent flow for thorough internal and external rinsing.

After the two-stage rinsing process, high-efficiency drying removes surface moisture from the workpiece. This drying process does not use compressed air. After rinsing, the movable water tank opens, clamps release, and the robot transfers the workpiece to the outlet conveyor pallet.

To extend rinsing time, this station features two positions. The robot places the workpiece in one position while retrieving a previously rinsed workpiece from the other position. Fixed blow-drying nozzles provide supplementary drying as needed.

This station features an independent water tank, pump, and filtration system operating at ambient temperature. Two pallet types accommodate stator and rotor variants with manual changeover.

Stage 5: Vacuum Drying (5ST) — ≤10 mbar

The workpiece and pallet are conveyed into the vacuum chamber. The upper movable vacuum hood extends via cylinder actuation to form a sealed chamber with the bottom fixed hood.

The vacuum pump evacuates the chamber, reducing pressure to as low as 10 mbar. This lowers the saturated steam temperature, evaporating residual moisture from all surfaces and internal cavities.

After vacuum drying, the chamber is vented, the movable hood returns to its original position, and the conveyor transports the workpiece to the next station.

Stage 6: Cooling & Unloading (6ST)

The workpiece is conveyed into the cooling channel. Forced air cooling and fans reduce the component temperature to room temperature ±3°C. The cooling channel accommodates up to 10 workpieces in queue. The system measures three or more positions on each workpiece to ensure temperature uniformity (maximum-to-minimum temperature difference ≤1°C) and consistent temperature across consecutive workpieces (temperature variation ≤3°C between workpieces).

After cooling, the workpiece and pallet are conveyed to the unloading position. The operator removes the workpiece. Empty pallets are returned to the loading position via the lower-layer conveyor for pallet circulation. This station features workpiece presence detection, room temperature monitoring, and workpiece surface temperature monitoring.

High-Pressure Cleaning Technology

The system features a high-pressure cleaning system with exceptional capability:

This high-pressure capability enables effective removal of stubborn machining chips, graphite particles, and iron powder from blind holes and complex internal cavities that conventional cleaning cannot reach.

Vacuum Drying Technology

The system features advanced vacuum drying for thorough moisture removal:

Vacuum drying ensures components are completely dry for downstream operations without the risk of water spots or corrosion.

Technical Cleanliness Control

For commercial vehicle transmission retarder manufacturing, cleanliness of stator and rotor components directly affects retarder performance and reliability.

The system is designed to meet strict cleanliness requirements:

Advanced Filtration Management

The system employs a three-stage (or higher) filtration system:

Filtration Features:

• Filter blockage alarm displayed on HMI

• Non-stop filter change capability (bag change ≥15 days; high-pressure filter change ≥30 days)

• Differential pressure monitoring to detect bag damage or blockage

• Filter bags: 180 × 810 mm size

• Easy cleaning and replacement access

Oil Separation System

The system features comprehensive oil separation capability:

• Configuration: 2 float-type oil skimmers + 1 belt-type oil skimmer

• Oil Skimmer Replacement Cycle: ≥2 years

• Surface Oil Coverage: <10% of liquid surface area

• Oil Removal Rate: ≥99%

• Float Reliability: Stable operation ≥3 months with accurate liquid level following

Intelligent Manufacturing Integration

The system supports Industry 4.0 requirements through comprehensive data connectivity:

MES Communication

• Siemens S7-1500 PLC with PROFINET

• Two independent Ethernet ports with separate IP addresses

• OPC UA communication for data acquisition

• Remote diagnostic capability for online troubleshooting

Operator Interface

• Siemens TP1200 touch screen (12" minimum)

• Chinese/English language switching

• 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

Data Acquisition

• Equipment fault monitoring (time, frequency)

• Production count and cycle time recording

• Equipment uptime tracking

• Power consumption monitoring (SIEMENS smart meter)

• Water and air consumption monitoring

Application Case

Complete Cleaning Solution

Big Bird Industrial provides comprehensive engineering solutions including:

Process Development

• Component analysis for stator/rotor components

• Cleaning process design for transmission retarder parts

• Cleanliness requirement evaluation

Equipment Integration

• High-pressure cleaning systems (35 MPa, max 50 MPa)

• Turbulent cleaning technology

• Vacuum drying systems

• Multi-stage filtration management

• Conveyor and material handling systems

Smart Manufacturing Connection

• MES interface (OPC UA)

• QR code traceability

• Production data acquisition

Why Choose Big Bird Industrial

Transmission Component Experience

Big Bird Industrial specializes in precision cleaning solutions for automotive and commercial vehicle powertrain components, with proven experience in stator and rotor cleaning for transmission retarder systems.

High-Pressure Cleaning Technology

The system delivers high-pressure cleaning up to 35 MPa (max adjustable 50 MPa) — significantly higher than conventional cleaning systems — ensuring effective removal of stubborn contaminants from blind holes and complex internal cavities.

Vacuum Drying Technology

The system achieves vacuum levels as low as 10 mbar for complete moisture removal from all surfaces, blind holes, and internal cavities — eliminating the risk of water spots or corrosion.

System-Level Engineering Capability

The company provides complete solutions from cleaning process development to production integration, including high-pressure cleaning, vacuum drying, intelligent traceability, 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.

Mixed-Model Production Support

The system handles 12 workpiece variants with pallet changeover and QR code recognition, supporting flexible production for multiple part families.

FAQ

What components does this cleaning system process?

This system is designed for stator and rotor components used in commercial vehicle transmission retarder systems — 12 variants in ductile iron and gray iron, weighing 2.43–10.5 kg.

What cleaning pressure is available?

The system delivers high-pressure cleaning up to 35 MPa (minimum), with maximum adjustable pressure of 50 MPa via VFD control.

What vacuum level is achieved for drying?

The system achieves vacuum levels as low as 10 mbar for complete moisture removal from all surfaces and internal cavities.

What contaminants can be removed?

It removes metal chips, graphite particles, iron powder, cutting fluid residues, and oil contamination from surfaces, blind holes, and internal cavities.

What cleanliness levels can be achieved?

Total residual contamination ≤0.55 mg/kg; metal particles ≤600 μm; non-metal particles ≤1200 μm. Surface cleanliness verified by white tissue paper wipe (5 wipes, no discoloration).

Is the system customizable?

Yes. All parameters—including cycle time, cleaning pressure, temperature, and automation level—are customizable per customer production line requirements.

What is the typical cycle time?

The system delivers ≤2 minutes per piece, supporting high-volume production for commercial vehicle powertrain manufacturing.

Stator/Rotor Cleaning in Commercial Vehicle Transmission Manufacturing

Stator and rotor components in transmission retarder systems require precise cleaning to ensure reliable performance. These precision components with complex geometries—including blind holes, internal cavities, and fine surface finishes—demand advanced cleaning technologies to remove metal chips, graphite particles, and machining residues. High-pressure cleaning systems deliver the cleaning power necessary for thorough contaminant removal from these critical components.

High-Pressure Cleaning (35 MPa) for Precision Powertrain Components

High-pressure cleaning at 35 MPa (max adjustable 50 MPa) provides superior contaminant removal for precision transmission components. The extreme pressure effectively dislodges stubborn particles from blind holes, internal cavities, and complex geometries that conventional low-pressure cleaning cannot reach. Variable frequency drive control allows pressure adjustment for different component requirements and contamination levels.

Vacuum Drying Technology (≤10 mbar) for Component Protection

Vacuum drying at ≤10 mbar ensures complete moisture removal from all surfaces and internal cavities without thermal stress or water spots. This low-pressure environment lowers the saturated steam temperature, evaporating residual moisture efficiently. The result is thoroughly dry components ready for downstream operations, eliminating the risk of corrosion, water spots, or contamination from moisture.

Filtration and Fluid Management in High-Pressure Cleaning

Effective filtration is essential for maintaining cleaning quality in high-pressure cleaning systems. Three-stage filtration configurations with drum filters, bag filters, and in-line filters protect high-pressure pumps from damage while maintaining cleaning fluid cleanliness. Non-stop filter change capability ensures continuous operation without production interruptions. Filtration accuracy down to 5 μm ensures cleaning fluid quality is maintained for consistent cleaning results.

Specification Details