Automotive Crankshaft Multi-Station Final Cleaning System

Systema Industriale Purificationis Finalis Multistationis pro Axis Crank Avium Magnarum est elaboratum ad purificationem finalem axis crank automobilium post operationes machinationis et politurae oleosa. Systema removet liquida sectionis, fragmenta metallica, contaminantes oleosi, et residua particulata ex galeriis oleosis, foraminibus filetatis, et omnibus superficiebus externis antequam ad coniunctionem.

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

Workpiece Applications

Systema accommodat componentes axis crank automobilium:

Omnes opuscula sunt automobilium axis curvi pro applicationibus fabricae motorum. Systema est constructum cum facultate manualis mutationis pro variantibus additis axis curvi per substitutionem fixurae, adaptationem programmatum, et modificationem trajectoriae robotis.

Productio automatica mixta modello

Systema productionem automaticam mixtam modellorum suportat cum:

Inpositio automatica

• Robotis gantry automaticus opusculum ponit in sedibus localis V-block ad stationem onerandi

• Mechanisma impellens glissans opusculum transferre ad positionem robotis capiendi

• Efflatio foraminis centralis ante apprehensionem robotis

• Systema identificationis opusculorum (basatum in commutatoribus) pro variantibus iam existentibus

• Praeservatio errorum: detectio axialis, detectio radialis, et detectio orientationis extremi magni/petiti

• Tutela securitatis cum interblocco electronicis

Systema Robotici

• Robotis ABB IRB6700-200/2.6 6-axialis

• IP67 Praesidium

• onus maximum 100 kg

• 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)

Processus Mundandi Multistadium

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

Stadium 1: Impositio (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.

Gradus 2: Purificatio Ultrasonica et per Asperginationem (2ST) — 0,5 MPa

Robot transmittit opus ad palletam stationis purificationis ultrasonicae. Palleta deprimatur, opus in vas purificationis immersum faciens, quod iam antea cum liquido purificante impletum est. Purificatio ultrasonica (25 kHz) contaminantes ab omnibus superficiebus et internis canaliculis removet.

Post purificationem ultrasonicam, aspergines ex utraque parte opus superficiem aspergunt. Post purificationem, machina elevans opus sublevat, et robot opus ad stationem sequentem transferre potest.

Gradus 3: Purificatio ad Altam Pressionem in Puncto Fixo (3ST) — 15–20 MPa (Maxime 28 MPa)

Robot opus ad palletam stationis purificationis ad altam pressionem transferre potest. Modulus triaxialis XYZ positionem asperginum ad purificationem foraminum centralium in utroque extremo determinat.

Post cleaning of central hole, servo motor drives clamping arms to grip workpiece via centers at both ends, while locating pins engage locating pin holes. Pallet descends, and clamping mechanism rotates workpiece to specified angle.

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

Spindle features automatic nozzle change with three nozzle types: straight nozzles, fan nozzles, and angled nozzles, each with dedicated nozzle holders.

Stage 4: Spray Rinsing (4ST)

Robot transfers workpiece to rinsing station pallet. Servo motor drives clamping arms to grip workpiece via centers at both ends, while locating pins engage locating pin holes. Pallet descends, and clamping mechanism rotates workpiece to specified angle.

Modulus XYZ triaxialis perficit lavationem puncti fixi et lavationem scanning super superficies opus et galeriae olei. Post lavationem, dyspensatores expiratorii exsiccant opus. Deinde robotus transfert opus ad stationem sequentem.

Axis portat mutuationem automaticam dyspensatorum cum tribus generibus dyspensatorum: dyspensatoribus rectis, dyspensatoribus ventorum, et dyspensatoribus obliquis.

Gradus 5: Punctum Transferendi (5ST)

Robotus ponit opus purgatum super palletam transferendi. Systema convectivum catenarum transfert opus ad stationem sequentem.

Gradus 6: Exsiccatio Aere Calido (6ST)

Opus et palleta conducuntur ad stationem exsiccationis aere calido. Cylindri positionis fixant palletam in positione. Cylindri movent cultrum aeris sursum et deorsum trans axem curvatum pro exsiccatione perfecta.

Post exsiccationem, omnes cylindri revertuntur ad positiones suas originarias, et opus conducitur ad stationem sequentem.

Gradus 7: Exsiccatio Sub Vacuo (7ST)

Opus et palleta ad stationem siccationis sub vacuo transportantur. Cylindri positionis palletam in situ constringunt. Superior velum vacuum mobile descendit ut cameram hermeticam cum palleta formet. Machina vacuum cameram evacuat et vacuum per tempus praefinitum servat, umorem residuum ab omnibus superficiebus et canaliculis internis removens.

Post siccationem sub vacuo, omnes cylindri ad positiones suas originales revertuntur, et opus ad stationem sequentem transportatur.

Fase 8: Exoneratio (8ST)

Opus et palleta ad positionem exonerandam transportantur. Operator ex opere removet. Mutatio manualis blocorum localium palletae necessaria est ubi variantes operis mutantur.

Ventilator aerem ad opus efflat (cum calefactione temperaturae regolabili). Cortina lucis salutarem operatorem protegit. Mechanismus localis opus ad marcationem laseralem disponit (marcator laser a cliente praebitus).

Tecnologia purgationis ad altam pressionem

Systema purgationem ad altam pressionem cum facultate egregia habet:

Controlus Puritatis Technicae

In fabrica motorum automotive, puritas galeriarum olei axis cami et superficierum directe afficit fiduciam et functionem motoris.

Systema ad strictas exigentias munditiae designatum est:

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:

• Omnes sacculi filtrantes cum magneticis virgis pro pulvere particulae remotione

• Griddes magneticis in punctis fluxus reditus machinae

• Allarmum obstructionis cum commutatore manualem/mutatione sine interruptione productionis

• Capacitas ad mutandum filtrum sine intermissione

Intelligent Manufacturing Integration

Systema ad requisita Industriae 4.0 suffragat per integram connexione datorum:

Communicatio cum MES

• Interfacs Ethernet RJ-45

• Protocolum datum apertum pro integratione MES

• Capacitas ad ascensum et descensum datum productionis

Interfacing operatoris

• HMI Siemens cum display coloratum

• Status apparatus et ostensio defectuum

• Allarma auditiva et visualia (rubea/flava/viridia)

• Programma PLC cum protectione triplex per password

• Monita pro maintenance diei cum escalatione (operator non potest purgare, confirmatio magistri requiritur)

Systema regens

• SIEMENS S7-1500 PLC

• Communicatio bus PROFINET cum VFDs et I/O campi

• Gradus protectionis componentium electricorum: IP54

• Configuratio metri potentiae pro monitoratione energiae

Applicationem Causa

Solutio Purificationis Completa

Big Bird Industrial praebet solutiones technicas comprehensivas, inter quas:

Developementum Processus

• Component analysis for automotive crankshafts

• Cleaning process design for final cleaning applications

• Aestimatio necessitatum de munditia

Integratio Instrumentorum

• Multi-station cleaning systems

• Ultrasonic cleaning technology (25 kHz)

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

• Vacuum drying systems

• Systema de tractatio per convectores et palletas

• Automatic nozzle change systems

Coniunctio Fabricationis Intellegentis

• MES interface

• Acquisitio datum productionis

• Monitoratio Energiae

Cur Big Bird Industrial eligeres

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

Systema integrat purgationem ultrasonican, purgationem per aspersionem, purgationem ad punctum fixum ad altam pressionem (15–20 MPa, maxime 28 MPa), lavationem, siccationem per aerem calidum, et siccationem sub vacuo in unica configuratione compacta octo-stationum pro eliminatione comprehensiva contaminantium.

Purgatio ad Altam Pressionem cum Mutatione Automatica Dysi

Systema habet purgationem ad altam pressionem in tribus axibus XYZ cum facultate mutationis automaticae dysi (dysae rectae, a ventaglio, et obliquae) pro purgatione praecisa omnium galeriarum olei, foraminum centralium, et superficierum.

Capacitas Ingenieriae ad Nivellem Systematis

Societas solutiones completas praebet a developmento processus purgationis usque ad integrationem in productione, incluse purgationem ultrasonicam, purgationem ad altam pressionem, siccationem sub vacuo, et connexionem ad MES.

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

• Evolutio Processus Purgationis

• Customized fixture and automation design

• Factory layout and production flow integration

Întrebări frecvente

Quae componentia hoc systema purgat?

Hoc systema est designatum pro axis automobilium usque ad 800 mm longitudinem, diametrum oscillans Φ250 mm, et pondus 60 kg pro fabrica motorum.

Quae pressio purgationis disponibilis est?

Systema praebet purgationem ad altam pressionem ad 15–20 MPa (maxime 28 MPa adiustabilis) cum controllo intelligenti VFD, et purgationem per aspersionem ad 0.5 MPa.

Quae technologiae purgationis integratae sunt?

Sistemo integras ultrasonan purigon (25 kHz), spraj-purigon, alt-preman fiksan punktan purigon, spraj-rincon, varman aeran sekigon kaj vakuan sekigon en 8-stacia konfiguro.

Quae contaminantia removeri possunt?

Ĝi forigas tranĉ-fluojn, metalajn ŝipojn, oleajn kontaminojn kaj partiklan reston el ole-kanaloj, centraj truoj kaj ĉiuj eksteraj surfacoj.

What cleanliness levels can be achieved?

Tuta resta kontamino ≤10 mg; kontamino de ole-kanaloj ≤3 mg; maksimuma partikla grandeco ≤0,6 mm; kun striktaj limoj por partikla kvanto laŭ ĉiu grandeca intervalo.

Num integratio productionis automaticae suportatur?

Jes. La sistemo havas aŭtomatan ŝarĝadon per gantro-robota interfaco, aŭtomatan identigon de laborpeco, erar-prizorgon kaj kapablon komuniki kun MES.

What is the typical cycle time?

La sistemo liveras ≤180 sekundojn por ĉiu peco (inkluzive de robotŝarĝado/malŝarĝado), kun cikla tempo adaptebla laŭ la postuloj de la produktolinio.

Purificatio Finalis Axis Crank in Fabricatione Motorum Automobilium

Nettoyage final de la manivelle est un processus critique entre l’usinage et l’assemblage dans la fabrication des moteurs automobiles. Les manivelles avec des galeries d’huile complexes, des trous centraux et des surfaces de précision exigent des technologies de nettoyage avancées pour éliminer les fluides de coupe, les copeaux métalliques, les contaminants huileux et les résidus particulaires. Le nettoyage par ultrasons atteint les passages internes auxquels le nettoyage par pulvérisation conventionnel ne peut pas accéder, tandis que le nettoyage à haute pression garantit l’élimination complète des contaminants tenaces sur toutes les surfaces.

Nettoyage par ultrasons et à haute pression pour composants de manivelle

Crankshaft automobilium difficultates peculiares propter geometrias complexas, galerias olei, et superficies praecisas. Pulverizatio ultrasonica efficaciter removet contaminantes ex ductibus internis et foraminibus caecis, dum pulverizatio altae pressionis (15–20 MPa, max 28 MPa) praebet vim pulvere necessariam ad residua obstinata. Series pulvere multistadii cum siccatione integrata certificantur eliminationem completam contaminantium et protectionem contra corrosionem.

Tecnologia siccationis sub vacuo pro protectione componentium

Tecnologia siccationis sub vacuo certificat eliminationem completam umoris ab superficiebus crankshaftrum et ductibus internis sine stress thermico aut maculis aquae. Ambiens pressionis diminutae temperaturam vaporis saturati minuit, sic umorem residuum efficiens evaporare. Combinata cum siccatione aere calido, siccatio sub vacuo eliminat periculum corrosionis et macularum aquae in superficiebus praecisis.

Tecnologia filtrationis magneticae pro removale particulae pulveris

Filtratio efficax est essentialis ad qualitatem purgationis in purgatione axis cami servandam. Separatores magneticis et filtrorum sacculorum cum baculis magneticis particulas pulveris ferrosas ex liquido purgatorio efficebant, pompas et dysprosas protegentes dum resultata purgationis constantia servantur. Facultas mutationis filtrorum sine intermissione cum alarum obstruendarum certa operationem continuam sine interruptionibus productionis assicurat.

Specificationes technicae