Systema Purificationis Intermediae Capitis Cylindrici Automobilis

Systema Intermedium de Purificatio Capitis Cylindri Industrialis ‘The Big Bird’ est elaboratum ad purificationem post-machinationem capitum cylindrorum in fabrica motorum diesel robustorum. Hoc systema removet residua machinationis antequam processus subsequentes incipiant, et suadet productionem automaticam mixtam sine interventu manualem.

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

Workpiece Applications

Hoc systema accommodat multas variantes capitum cylindrorum pro fabrica motorum diesel robustorum:

Omnes opuscula sunt sub-assembly capitis cylindri pro applicationibus motorum diesel graviorum. Systema suadet productionem automaticam mixtam sine mutatione manu facta.

Productio automatica mixta modello

Hoc systema supportat productionem automaticam mixtam modello cum sequentibus facultatibus:

Recognitio Codicis QR

Apparatus lectionis codicum QR legunt automatico modo identificationem opusculi in tempore onerandi. Systema eligit programmam purgationis aptam secundum informationem codicis QR. Capacitas memoriae sustinet usque ad 256 variantes numerorum partium. Imprimens automatica addita codicum bar (2 unitates) configuratur pro traciabilitate productionis.

Tractatio Bina Opusculorum

Systema habet duos robots sex-axiales qui possunt tractare duos capita cylindri simul, efficiens productionem duplicatam cum tempore cycli 76 secundis pro duobus opusculis (38 secundis pro singulo opusculo).

Automatic Model Changeover

Fixturae, dyspensae et componentes positionis ita sunt designatae ut omnes variantes capitum cylindri recipiant sine interventu manu facto. Superficies localis fixturarum habent purgationem automaticam ut damnum opusculi ab scissuris impediatur.

Communicatio cum MES

Systema interfaciens est cum MES pro tractatione productionis, acquisitione datorum, et actualizatione status secundum generales requisitiones technicas fabricatorum automobilium.

Processus Mundandi Multistadium

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

Stadium 1: Impositio (1ST)

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

The entrance 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

Post pulitura turbulenta, aperitur valvula de effusio cisternae pro effusione rapida. Robot ponit opuscula ad dysposita orificia magni diametri pro purgatione obturatorum in iaculum aquae, ut omnes vias refrigerationis bene purgentur.

Gradus 4: Purificatio in Puncto Fixo (4ST) — 1,5 MPa

Post purgationem obturatorum in iaculum aquae, opuscula ponuntur ad tabulas dyspositorum in puncto fixo. Unumquodque dyspositum accurate alignatur cum foraminibus correspondentibus in capite cylindri, ut omnes vias directe purgentur. Robot mutat orientationem opusculorum ut unamquamque superficiem alignet cum tabulis dyspositorum correspondentibus, et machina purgandi continuat implere cisternam turbulenta pro cycli sequentis.

Gradus 5: Purificatio Precisa in Iaculo Aquae (5ST) — 0,6 MPa

Robotus #1 ponit duos opuspieces simul in palettas positionis in hac statione. Cylindri extendunt nozzle ad purgandum obturatorem iaculi aquae dum simul purgant opuspiece precise. Haec statio habet duas positiones ad tempus purgationis precise producendum. Robotus #1 ponit opuspieces in una positione dum Robotus #2 tollit opuspieces iam purgatos ex altera positione. Haec statio habet cisternam aquae, pompam et systema filtrationis independentia.

Gradus 6: Siccatio ad Punctum Fixum (6ST) — 0,2–0,4 MPa

Robotus #2 tenet opuscula et movet ea ad stationem siccationis per flatum. Dum transferuntur, robotus mutat orientationem opusculorum pro drenagio obliquo. Deinde robotus ponit opuscula ad casses dyspensatorias fixas ut siccet omnes foramina et canales per flatum directum. Quaelibet superficies habet tabulas dyspensatorias correspondentes. Post siccationem per puncta fixa, robotus perficit siccationem per flatum exploratorium super superficies opusculorum. Post siccationem, Robotus #2 ponit opuscula super convectorem rotulorum gravitatis ad exitum machinae, et baculi transmittentes simul promovent utrumque opusculum ad stationem sequentem.

Gradus 7: Siccatio Secundaria per Flatum (7ST)

Baculi transmittentes deferunt duo opuscula in cameram siccationis secundariae per convectorem rotulorum gravitatis. Cylindri superiores extendunt casses dyspensatorias pro siccatione per flatum exploratorium fixo super opusculum totum. Post siccationem secundariam per flatum, baculi transmittentes simul promovent utrumque opusculum ad stationem sequentem.

Gradus 8: Siccatio Sub Vacuo (8ST)

Transfer bars convey two workpieces into the vacuum chamber via 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 retracts, 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.

Controlus Puritatis Technicae

In fabrica motorum diesel graviorum, puritas canalium internorum directe affectat fiduciam et praestantiam motoris.

Systema ita designatum est ut exigentias strictas puritatis pro singulis canalibus capitis cylindri impleat:

Gestio Advanced de Filtratio

Systema usus est tripartita filtratione pro circuitu lavandi et bipartita filtratione pro circuitu lavandi praecisi:

Filtratio Circuitus Lavandi (Tripartita):

• Fase 1: Filtrum tamburi — 1.500 L/min, 50 μm, rete ex accipitro inox, cum auto-retrofluentia et carro chipporum

• Fase 2: Filtrum automaticum retrofluentis — 30 μm, cum separatore magnetico retrofluenti

• Stagium 3: Filtrum sacculare — 900 L/min, 10 μm, textilis non intextus (1 in subsidio + 1 in usu), cum alarma obstruendi

Filtratio Circuitus Lavandi Praecisi (Bipartita):

• Fase 1: Filtrum cestelli — 300 L/min, 40 retis, rete ex nylon, cum alarma obstruendi

• Fase 2: Filtrum sacculare — 300 L/min, 10 μm, textilis non intextus (1 in subsidio + 2 in usu), cum alarma obstruendi

Filtration Features:

• Omnia filtra habent alarma obstruendi quae ostenduntur in HMI

• Filter replacement does not affect normal equipment operation

• Separatio automatica fluidi purgationis ab squamis et residuis inutilibus

• Carro mobilis chipporum pro facili ablatione

Systema Robotici

Systema utitur duobus robotis FANUC ad efficiens manendum bina opera:

Intelligent Manufacturing Integration

Systema ad requisita Industriae 4.0 suffragat per integram connexione datorum:

Communicatio cum MES

• Supportus protocoli OPC UA

• Secutio operis per codices QR

• Renovatio status productionis

Collectio Datorum

• Monitoratio defectuum instrumentorum (tempus, frequentia)

• Registratio numeri productorum et temporis cycli

• Monitoratio temporis operationis instrumentorum

• Monitoratio consumptionis electricae (metrum intelligens SIEMENS)

Interfacing operatoris

• 15″ TFT colour touch screen (minimum)

• Lingua sinica interface

• Workpiece information display

• Selectio programmatum purgationis

• Monitoratio progressus purgationis

• Exhibitio temperaturae et pressionis

• Diagnosis defectuum et exhibitio allarum cum directionibus ad remedium

• Monitoratio altitudinis liquidi in vase et allarma

Sapientia Caracteres

• Lubricatio automatica ad intervalla programmanda

• Monita automatica de maintenance in HMI

• Capacitas diagnosticorum remotorum

Applicationem Causa

Solutio Purificationis Completa

Big Bird Industrial praebet solutiones technicas comprehensivas, inter quas:

Developementum Processus

• Analysis componentium pro capitibus cylindricis

• Design del processo de cleaning

• Aestimatio necessitatum de munditia

Integratio Instrumentorum

• Systemata purgationis robotica cum tractatione duplicis operis

• Turbulent cleaning technology

• Systemata purgationis obturatorum iaculatorum aquarum

• Purgatio ad altam pressionem in puncto fixo

• Technologia siccationis per vacuum

• Gestio multifasa filtrationis

• Automatizata Manipulatio Materialium

Coniunctio Fabricationis Intellegentis

• Interfacs MES (OPC UA)

• Traciabilitas codicis QR

• Acquisitio datum productionis

Cur Big Bird Industrial eligeres

Experientia in componentibus motorum robustorum

Big Bird Industrial specializatur in solutionibus purgationis praecisarum pro componentibus automotive transmissorum potentiae, cum experientia probata in purgatione capitum cylindricorum pro applicationibus motorum diesel robustorum.

Tractatio robotica duplicis operis

Hoc systema duos robots FANUC habet, qui duo capita cylindrica simul tractare possunt, tempora cycli rapida 38 secunda per partem praebentes, et OEE ≥95% pro productione magnae voluminis.

Tecnologia Lavandi Multistadium

Systema combinat purificationem turbulenter, purificationem per obturatorem iaculi aquosi, purificationem in puncto fixo, purificationem praecisam iaculi aquosi, exsiccationem per insufflationem, et exsiccationem sub vacuo ad eliminationem completam contaminantium ex geometriis capitis cylindri complexis.

Capacitas Ingenieriae ad Nivellem Systematis

Societas solutiones integras praebet a developmento processus purificationis usque ad integrationem in productione, includente manuplationem robotici, purificationem ad altam pressionem, exsiccationem sub vacuo, et connexionem ad systema 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

Capacitas ingenieriae non standardis societatis permittit ut quodlibet systema lavandi ad geometriam specificam componentis, ad tempora cycli, ad normas munditiae, et ad gradum automationis adaptetur.

Conformitas cum Normis

Omne apparatus ad normas ISO 13849, IEC 62061 (SIL3), GB 5226.1, et ad normas securitatis Sinicas et internationalis applicabiles conformatur. Vasa sub pressione ab auctoritatibus inspectionis tertiarum partium certificata sunt.

Întrebări frecvente

Quae componentia hoc systema purgat?

Hoc systema ad sub-assembly capitis cylindri pro modellis motorum diesel graviorum designatum est.

Quae contaminantia removeri possunt?

Eliminat fragmenta metalli, particulas machinationis, residua liquidi sectionis, et contaminationem internam ex galeriis olei, ductibus combustibilis, portubus admissionis/exhalationis, et iaculis refrigerationis.

Potestne purgare iacula aquosa et galerias olei?

Ita. Systema combinat purificationem turbulenter, purificationem per obturatorem iaculi aquosi, et purificationem in puncto fixo ad attingendos omnes ductus internos, inter quos galeriae olei bracchii oscillantis, galeriae reditus combustibilis, galeriae reditus olei, portus admissionis/exhalationis, et iacula aquae refrigerationis.

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 (76 s/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

Nettoyage intermédiaire de la culasse est un processus critique entre l’usinage et les opérations suivantes dans la fabrication de moteurs diesel lourds. La géométrie complexe des culasses—y compris de multiples galeries d’huile, canaux de carburant, orifices d’admission/échappement et chemises d’eau de refroidissement—exige des technologies de nettoyage avancées pour éliminer les résidus d’usinage, les copeaux métalliques et les contaminants provenant des fluides de coupe. Les fabricants modernes de moteurs exigent des niveaux de propreté stricts dans les passages internes afin d’assurer des performances fiables du moteur, une efficacité énergétique optimale et le respect des normes d’émissions.

Nettoyage turbulent pour géométries complexes de culasse

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

Systemata filtrationis efficacia sunt fundamentalia ad qualitatem netti consistentem in netti capitis cylindrici servandam. Configurationes filtrationis tripartitae—quae filtros tamburi, filtros automaticos retro-lavantes, et filtros sacciformes combinant—operationem continuam cum mutationibus filtrorum non intermissis permittunt. Accuratio filtrationis usque ad 10 μm qualitatem liquidi netti servat, pericula recontaminationis minuit, et vitam liquidi prolongat.

Specificationes technicae