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.

Productio automatica mixta modello

Systema productionem automaticam mixtam modellorum suportat cum:

Recognitio Codicis QR

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

Systema inspectionis visionis

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

Mutatio paleae manu facta

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

Erogorum Vitatio

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

Processus Mundandi Multistadium

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

Stadium 1: Impositio (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.

Post removal of the workpiece by the robot, the empty pallet returns to the loading position, prepared for the next workpiece. This station includes workpiece orientation detection, presence detection, QR code scanning, and vision inspection for part identification. Two pallet types support all workpieces, with manual changeover between stator and rotor variants.

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

The 6-axis robot grasps the workpiece and transfers it into the turbulent cleaning tank, pre-filled with cleaning fluid. The robot dynamically adjusts workpiece orientation while surrounding nozzles direct turbulent flow to clean all surfaces.

Post lavatione turbulenta, valvula effluens aperitur ut cisterna cito exhauriatur (tempus effluendi ≤5 secundae). Robot movet opus ad casses dyspensatorias fixas, quae secundum foraminum dispositionem operis sunt ordinatae. Robot mutat positionem operis ut singulae superficies cum panelibus dyspensatoriorum congruant, sic omnia foramina et cavitates internae exacte lavantur.

Duo panelia cassium dyspensatoriorum accommodant familias operum magnarum et parvarum, inter quae commutatio manu fit. Post lavationem, robot transferit opus ad stationem sequentem. Machina lavans continuat cisternam turbulenter implere, ut parata sit pro opere sequenti.

Gradus 3: Lavatio Altae Pressionis (3ST) — ≥35 MPa (Maxime Regulabilis 50 MPa)

Robot transferit opus ad stationem lavationis altae pressionis. Robot mutat positionem operis ut cum dyspensatoribus fixis altae pressionis congruat, et lavationem altius pressionis in areis criticis perficit, inter quas foramina caeca et cavitates internae.

Hoc stationem nozzulas lineares et nozzulas anguli 90° habet ad universalem tegendam superficiem. Nozzulae rotatoriae ad altam pressionem (diameter cortinae pulveris ≥60 mm) praebent purgationem per scansionem in superficiebus operis.

Post purgationem ad altam pressionem, robotus operis transfert ad stationem sequentem, dum inclinatio ad effundendum aquam fit durante transitu.

Fase IV: Rinsing Universale (4ST) — Pulverizatio Rinsing + Immersio Turbulenta Rinsing + Siccatio Altae Efficientiae

Robotus operis ponit super palletam positionis intra hanc stationem. Mechanismi constringendi operis firmant ipsum in positione.

Un tankum aquae mobilis extenditur ut involvat opus cum tanko lavationis fixo. Dyspensae fixae perfundunt opus. Simul, aqua lente implent tankum, immergens opus in liquorem lavandi et creans fluxum turbulatum ad lavationem internam et externam perfectam.

Post processum bini-rinsing, siccatio altae efficientiae umorem superficialem ex operis aufert. Hic processus siccationis non utitur aere compresso. Post rinsing, mobilis vas aquae aperitur, constringentes laxantur, et robotus operis transfert ad palletam convectorem exitus.

Ad augendam tempus lavationis, haec statio duas positiones habet. Robotus opus in unam positionem ponit, dum ex altera positione opus iam lavatum tollit. Fixae insufflationis tubae siccationem supplementariam praebent, ut opus sit.

Haec statio independentem aquae cisternam, pompam et systema filtrationis habet, quae ad temperaturam ambientem operantur. Duo palorum typi statoris et rotoris varietates accommodant, cum manualem commutationem admittunt.

Gradus 5: Siccatio sub vacuo (5ST) — ≤10 mbar

Opus et palus in cameram sub vacuo deferuntur. Superior mobilis campana sub vacuo per cylindri actionem extenditur, ut cameram hermeticam cum inferiori fixa campana constituat.

Pompa sub vacuo cameram evacuat, pressionem usque ad 10 mbar minuens. Hoc temperaturam saturatae vaporis demittit, ut umor residuus ab omnibus superficiebus et cavitatibus internis evaporet.

Post siccatione sub vacuo, camera aperitur, tegmen mobile ad positionem suam originalem revertitur, et convexus opus ad stationem sequentem portat.

Gradus 6: Refrigeratio & Expositio (6ST)

Opus in canalum refrigerationis portatur. Refrigeratio aere compulsivo et ventiles temperaturam componentis ad temperaturam ambientem ±3°C minuunt. Canalus refrigerationis usque ad 10 opera in fila capere potest. Systema tria aut plura loca in quolibet opere metitur ut uniformitas temperaturae (differentia inter maximam et minimam temperaturam ≤1°C) et consistentia temperaturae inter opera consequentia (variatatio temperaturae ≤3°C inter opera) certificetur.

Post refrigerationem, opus et pala ad positionem expositionis portantur. Operator opus tollit. Palae vacuae per convexitum inferiorem ad positionem onerationis remittuntur ut pala circuletur. Haec statio detectionem praesentiae operis, monitorationem temperaturae ambientis, et monitorationem temperaturae superficiei operis habet.

Tecnologia purgationis ad altam pressionem

Systema habet systema purgationis ad altam pressionem cum facultate egregia:

Haec facultas ad altam pressionem permittit eliminationem efficacem fragmentorum machinalium obstinatorum, particulae graphitae, et pulveris ferri e foraminibus caecis et cavitatibus internis complexis, quae systemata purgationis communia attingere non possunt.

Technologia siccationis per vacuum

Systema habet siccationem vacuum ad eliminandum umorem penitus:

Siccatio vacuum certificat componentes esse penitus siccos pro operationibus subsequentibus, sine periculo macularum aquarum aut corrosionis.

Controlus Puritatis Technicae

Pro fabrica retardatorum transmutationis vehiculorum commercialium, munditia componentium statoris et rotoris directe afficit functionem et fidem retardatoris.

Systema ad strictas exigentias munditiae designatum est:

Gestio Advanced de Filtratio

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

Filtration Features:

• Filter blockage alarm displayed on HMI

• Capacitas Mutandi Filtrum Sine Interruptione (Mutatio Sacci ≥15 Dies; Mutatio Filtri Altae Pressionis ≥30 Dies)

• Monitorium Pressionis Differentialis ad Detegendum Damnum Sacci vel Obstructionem

• Sacci Filtrantes: Dimensio 180 × 810 mm

• Accessus Facilis ad Purificationem et Substitutionem

Systema Separationis Olei

Systema Habet Capacitatem Comprehensivam Separandi Oleum:

• Configuratio: 2 skimmer olei typi flotantis + 1 skimmer olei typi cinguli

• Cyclum substitutionis skimmer olei: ≥2 anni

• Coperitura olei superficialis: <10% areae superficialis liquidi

• Rationem remotionis olei:  ≥99%

• Fiducia flotantis: Operatio stabilis ≥3 mensium cum exacta observatione nivelis liquidi

Intelligent Manufacturing Integration

Systema ad requisita Industriae 4.0 suffragat per integram connexione datorum:

Communicatio cum MES

• PLC Siemens S7-1500 cum PROFINET

• Duo foramina Ethernet independens cum adrectiviis IP separatis

• Communicatio OPC UA pro acquisitione datorum

• Capacitas diagnosticarum remotarum pro solutione problematum in reti

Interfacing operatoris

• Schermus tactilis Siemens TP1200 (minime 12" )

• Chinese/English language switching

• 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

Collectio Datorum

• Monitoratio defectuum instrumentorum (tempus, frequentia)

• Registratio numeri productorum et temporis cycli

• Monitoratio temporis operationis instrumentorum

• Monitoratio consumptionis electricae (metrum intelligens SIEMENS)

• Monitoratio consumptionis aquae et aeris

Applicationem Causa

Solutio Purificationis Completa

Big Bird Industrial praebet solutiones technicas comprehensivas, inter quas:

Developementum Processus

• Component analysis for stator/rotor components

• Cleaning process design for transmission retarder parts

• Aestimatio necessitatum de munditia

Integratio Instrumentorum

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

• Turbulent cleaning technology

• Vacuum drying systems

• Gestio multifasa filtrationis

• Systemata convectores et manuales tractationis materiae

Coniunctio Fabricationis Intellegentis

• Interfacs MES (OPC UA)

• Traciabilitas codicis QR

• Acquisitio datum productionis

Cur Big Bird Industrial eligeres

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.

Tecnologia purgationis ad altam pressionem

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.

Technologia siccationis per vacuum

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.

Capacitas Ingenieriae ad Nivellem Systematis

Societas solutiones integras praebet, a developmente processus purgationis usque ad integrationem productionis, incluse purgationem ad altam pressionem, siccationem sub vacuo, tracciabilitatem intelligentem, 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.

Subsidium Productionis Mixtae

Systema variantes operis duodecim tractat, cum commutatione palletarum et recognitione codicum QR, subsidens productionem flexibilem pro pluribus familiae partium.

FAQ

Quae componentia hoc systema purgat?

Hoc systema designatum est pro componentibus statoris et rotoris, quae in systematibus retardatoris transmissionis vehiculorum commercialium utuntur — duodecim variantes in ferro ductili et ferro griseo, gravantes 2,43–10,5 kg.

Quae pressio purgationis disponibilis est?

Systema purgationem ad altam pressionem praebet usque ad 35 MPa (minimum), cum pressione maxima regolabili 50 MPa per controllem VFD.

Quod nivellum vacui adhibetur pro siccatione?

Systema nivellum vacui attingit usque ad 10 mbar pro remotione completa umoris ab omnibus superficiebus et cavitatibus internis.

Quae contaminantia removeri possunt?

Removet fragmenta metalli, particulas graphitii, pulverem ferri, residua liquidi sectionis, et contaminationem olei ab superficiebus, foraminibus caecis, et cavitatibus internis.

What cleanliness levels can be achieved?

Contaminatio residualis totalis ≤0.55 mg/kg; particulae metallicae ≤600 μm; particulae non-metallicae ≤1200 μm. Puritas superficiei verificata per tergum papiraceum album (5 terga, nulla discoloratio).

Is the system customizable?

Ita. Omnes parametri—inclusis tempore cycli, pressione lavationis, temperatura, et gradu automationis—adaptabiles sunt secundum requisita lineae productionis clientis.

What is the typical cycle time?

Systema efficit ≤2 minuta per partem, adiuvans productionem magni voluminis in fabrica transmissorum vehiculorum commercialium.

Lavatio Statoris/Rotoris in Fabricatione Transmissorum Vehiculorum Commercialium

Componentes de estator et rotor in systematibus retardatoris transmissionis requirunt munditiam praecisam ut performance fidabilis certificetur. Haec componentia praecisa cum geometriis complexis—including foramina caeca, cavitates internae, et finissimae superficies—exigunt technologias munditiae provectas ad eliminandos fragmenta metalli, particulas graphitii, et residua machinationis. Systemata munditiae ad altam pressionem vim munditiae praebent quae necessaria est ad eliminandos contaminantes ex his componentibus criticis.

Munditia ad Altam Pressionem (35 MPa) pro Componentibus Praecisis Transmissionis

Munditia ad altam pressionem ad 35 MPa (maxime adiustabilis ad 50 MPa) praebet eliminationem superiorem contaminantium pro componentibus praecisis transmissionis. Pressio extrema efficaciter solvit particulas obstinatas e foraminibus caecis, cavitatebus internis, et geometriis complexis quas munditia ad pressionem inferiorem non attingere potest. Controllo per impulsum variabilem frequenticum permittitur adiustatio pressionis pro diversis requisitis componentium et gradibus contaminationis.

Technologia siccationis sub vacuo (≤10 mbar) pro protectione componentium

Siccatio sub vacuo ad ≤10 mbar certificat eliminationem perfectam umoris ab omnibus superficiebus et cavitatibus internis sine stress thermico aut maculis aquosis. Haec ambitus pressionis infimae temperaturam vaporem saturatum minuit, sic umorem residuum efficaciter evaporans. Ergo componentia per omnia sicca sunt, parata ad operationes subsequentes, et periculum corrosionis, macularum aquosarum, aut contaminationis ex umore tollitur.

Filtratio et administratio fluidorum in lavatione ad altam pressionem

Filtratio efficax necessaria est ad qualitatem purgationis in systematibus purgationis ad altam pressionem servandam. Configurationes filtrationis tripartitae, cum filtris rotundis, filtris sacciformibus et filtris in linea, protegunt pompas ad altam pressionem a damno, dum simul puritatem fluidi purgatorii conservant. Facultas mutationis filtrorum sine intermissione operationem continuam sine interruptionibus productionis permittit. Accuratio filtrationis usque ad 5 μm qualitatem fluidi purgatorii servat, ut resultata purgationis constanter bona sint.

Specification Details