New Energy Vehicle Integrated E-Drive Housing Robotic Cleaning System

The Big Bird Industrial Integrated E-Drive Housing Robotic Cleaning System is developed for post-machining cleaning of aluminum housings used in new energy vehicle electric powertrain manufacturing. The system removes machining and casting residues before final assembly and supports mixed-model production with automatic tool change for multiple workpiece variants.

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

Workpiece Applications

The system accommodates multiple integrated e-drive housing variants for new energy vehicle applications:

All workpieces are aluminium housings for new energy vehicle electric powertrain applications. The system is designed with automatic tool change capability, accommodating multiple workpiece variants through a fixture library system.

Automatic Tool Change & Mixed-Model Production

The system supports fully automatic mixed-model production with:

Recognitio Codicis QR

A COGNEX QR code scanning system automatically reads workpiece identification upon loading. The system selects the appropriate cleaning program based on the QR code information.

Systema inspectionis visionis

A COGNEX vision system identifies workpiece type and orientation, guiding the robot for precise gripping and handling.

Automatice ferramenta mutatur

Each robot is equipped with an automatic tool changer (Stäubli) and a fixture library capable of storing 4 fixture sets. The system automatically changes fixture based on workpiece identification, enabling seamless mixed-model production without manual intervention.

Configuratio Tribus Robotorum

Systema tribus robotis FANUC utitur, quorum opus coordinatum est:

• Robotus 1: Purgatio turbulenta + Purgatio altae pressionis rotatoria

• Robotus 2: Traditio purgationis ultrasonicae + Purgatio altae pressionis ad punctum fixum

• Robotus 3: Tractatio lavacri primarii + Lavacrum secundarium + Asciugatio aeris

Processus Mundandi Multistadium

Systema varias technologias purgationis in sequentia automatica undecim graduum coniungit:

Gradus 1: Onus

Robotus suprascriptus a linea automatica onerat automatico opus in palletam onerandam systematis purgationis. Systema convectivum transportat opus et palletam ad positionem ubi robotus capere potest.

Statio onerandi habet:

• Scansionem automaticam codicum QR pro identificatione operis (COGNEX)

• Systema visionis pro recognitione generis et orientationis operis (COGNEX)

• Butones initiationis duarum manuum, arrestus emergentis, et cortinae lucis tutelares

• Efflatio automatica aeris sedium locantium palletarum vacuarum post capionem a robotu

• Compatibilitas cum modis onerandi manualibus et automaticis

• Convectores rullantes elevantes ad utrumque extremum pro circulatione automatica palletarum

Gradus 2: Purgatio turbulenta et punctiformis (1,5 MPa)

Robotus 1 tenet opus et transferit illud in vasculum purgationis turbulentis, quod iam praesatur fluido purgatorio. Robotus flexibiliter mutat orientationem operis dum dysae fluxum turbulentem dirigunt ad omnes superficies purgandas.

During turbulent cleaning, the robot fixture engages water jacket hole plugs to prevent aluminum chips from entering the water jacket cavity during cleaning.

After turbulent cleaning, the drain valve opens for rapid drainage. 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 receive targeted cleaning.

After cleaning, the robot transfers the workpiece to the next station with tilt-drainage during transfer. The cleaning pump continues filling the turbulent tank so it is ready for the next workpiece.

Stage 3: Rotary High-Pressure Cleaning (40 MPa)

Robot 1 transfers the workpiece to the rotary high-pressure cleaning station. Rotating high-pressure nozzles deliver 40 MPa cleaning power to targeted areas of the workpiece. After cleaning, the robot transfers the workpiece to the next station with tilt-drainage during transfer.

Gradus 4: Nettoyage ultrasonique

Robot 1 transfert la pièce à usiner vers la palette de positionnement de la station de nettoyage ultrasonique. Le couvercle du bac ultrasonique se ferme automatiquement pendant le nettoyage. Cette station comporte deux positions, permettant à chaque pièce d’effectuer deux cycles de nettoyage ultrasonique.

Après le nettoyage ultrasonique, Robot 2 saisit la pièce à usiner depuis la palette de positionnement et la transfert vers la station suivante. Pour le changement de modèle, la palette de positionnement est remplacée manuellement ; sa conception est simple, légère et intègre un système mécanique d’empêchement d’erreur.

Gradus 5: Nettoyage haute pression à point fixe (40 MPa)

Robot 2 transfert la pièce à usiner vers la station de nettoyage haute pression à point fixe. Des buses linéaires fixes haute pression délivrent une puissance de nettoyage de 40 MPa sur les zones ciblées. Après le nettoyage, le robot transfert la pièce vers la station suivante avec un drainage incliné pendant le transfert. Un bref soufflage d’air élimine l’excédent de fluide de nettoyage avant que la pièce n’entre dans la station suivante.

Gradus 6: Rinçage par pulvérisation primaire

Robotus 2 ponit opus in palletam positionis in hac statione et retrahitur. Ostium stationis clauditur, et cassa dyspensatrix descendit ad perficiendam lavationem per aspersionem opus. Dyspensatrices speciales praebent lavationem per aspersionem pro tunicis aquae obturatorum pro quibusdam custodiis.

Post lavationem, cassa dyspensatrix redit ad positionem suam originalem, ostium stationis aperitur, et Robotus 3 tollit opus et transferit ad stationem sequentem. Pro mutatione modello, palleta positionis manu mutatur cum designo simplici et levi, quod includit praesidium contra errores duros.

Gradus 7: Lavatio Secundaria per Aspersionem

Robotus 3 tenet opus et perficit lavationem secundariam per aspersionem. Dyspensatrices speciales praebent lavationem per aspersionem pro tunicis aquae obturatorum pro quibusdam custodiis (directio lavandi opposita Gradui 6). Post lavationem, Robotus 3 transfert opus ad stationem sequentem.

Gradus 8: Siccatio per Flatum in Puncto Fixo

Robot 3 facit drenagium inclinatum dum transfert, deinde ponit opus in cassettis fixis ad foramina opus dispositis. Aer compressus praebet exsiccationem dirigentem omnium foraminum et canaliculorum.

Cassettae speciales pro foraminibus aquae praebent exsiccationem dirigentem pro certis custodiis, ut fluidum iaculi aquae plene exsiccari possit. Post exsiccationem ad punctum fixum, robot scannat superficies opus exsiccando. Post exsiccationem, Robot 3 ponit opus super palletam positionalem mundam et exsiccatam ad exitum.

Gradus 9: Exsiccatio Secundaria

Opus et palleta ad hanc stationem deferuntur. Ostium stationis clauditur, et cassettae exsiccare opus et palletam faciunt. Haec statio programmatem automaticum pro purgatione/exsiccatione palletarum habet, cum lineis purgationis et exsiccationis quae automato commutari possint.

Gradus 10: Exsiccatio Sub Vacuo

The workpiece is conveyed into the vacuum chamber. The upper vacuum hood extends via cylinder actuation, enclosing the workpiece in a sealed chamber. The vacuum pump evacuates the chamber, removing residual moisture from internal cavities and blind holes.

Stage 11: Cooling & Unloading

The workpiece is conveyed to the unloading point. Cooling fans reduce the component temperature to 20±3°C at the outlet. The outlet can hold up to 4 workpieces in queue. All outlet conveyors feature protective covers to prevent secondary contamination. Lifting roller conveyors at both ends return empty pallets to the robot placement position via the lower-layer conveyor. The system reserves space for future addition of a pallet cleaning and drying station.

Controlus Puritatis Technicae

For new energy vehicle electric powertrain manufacturing, cleanliness of e-drive housing internal passages directly affects the performance and reliability of electric drive units.

Hoc systema designatum est ad exigentias severas de puritate pro quolibet opusculo varianti implendas:

Qualitas siccationis verificatur per tergendum superficies operis cum carta filtrans — nullae notae umiditatis visibiles, nec nebula aquosa quando aer per omnes foramina efflatur.

Gestio Advanced de Filtratio

Systema utitur systemate filtrationis multi-graduum:

Omnes filtrati habent functiones praesignalis et signalis obstructionis. Skimmer olei fluitantis typi flotantis et skimmer olei fluitantis typi cinguli oleum fluitans e liquido lavandi removet, ut vitae liquidi longitudo augeatur.

Systema Robotici

Systema tria robotica FANUC utitur:

Omnes robotae plene aqua-resistentes sunt cum protectione IP67, constructione contra ruginem, et sensoribus hermeticis. Quisque robotus habet automaticum instrumentorum commutatorem (Stäubli) et aditum ad bibliothecam morsuum cum quattuor copiis morsuum. Accuratio repetitivae positionis ≤ ±0,2 mm. Superficies morsuum et clavuli localizantes evitant superficies machinatas (praeter superficies et foramina processuales).

Intelligent Manufacturing Integration

Systema ad requisita Industriae 4.0 suffragat per integram connexione datorum:

Communicatio cum MES

• PLC dotatus modulo interfaciei retis MES

• Supportus Communicationis per Ethernet

• Secutio operis per codices QR

• Acquisitio datum productionis

Interfacing operatoris

• Mitsubishi tactilis schermus HMI

• Praesentatio status realis apparatus cum visualizatione graphica

• Praesentatio parametrorum lavationis et eorum adaptatio

• Alarumae auditivae et visualis cum memoria historiarum alarumarum plus quam 500 (tempus, adiectus, causa, solutio)

• Modi operationis automaticus et manualis cum protectione interlock

Sapientia Caracteres

• Functio automatica circulationis in diebus festis ut fluidum non degradetur

• Capacitas diagnosticorum remotorum

• Reservatio datorum et interfacies coniunctionis retis

Applicationem Causa

Solutio Purificationis Completa

Big Bird Industrial praebet solutiones technicas comprehensivas, inter quas:

Developementum Processus

• Analysis Componentium

• Design del processo de cleaning

• Aestimatio necessitatum de munditia

Integratio Instrumentorum

• Multi-robot coordinated cleaning systems

• High-pressure cleaning technology (40 MPa)

• Ultrasonic cleaning systems (2 stations)

• Technologia siccationis per vacuum

• Automatic tool change systems with fixture library

• Gestio multifasa filtrationis

• Systemata convectores et manuales tractationis materiae

Coniunctio Fabricationis Intellegentis

• MES interface

• Traciabilitas codicis QR

• Acquisitio datum productionis

Cur Big Bird Industrial eligeres

New Energy Vehicle Component Experience

Big Bird Industrial specializes in precision cleaning solutions for automotive powertrain components, with proven experience in new energy vehicle e-drive housing cleaning for multiple electric powertrain applications across 9 workpiece variants.

Multi-Robot Cleaning Technology

The system utilizes three coordinated FANUC robots with automatic tool change capability and fixture library storage, enabling efficient cleaning of complex e-drive housing geometries with multiple cleaning technologies in a single production sequence.

Integrated Cleaning Technologies

Systema combinat purificationem turbulenta (1,5 MPa), purificationem rotatoriam ad altam pressionem (40 MPa), purificationem ultrasonica in duobus stationibus, purificationem ad altam pressionem in puncto fixo (40 MPa), lavationem per aspersionem in duobus gradibus, exsiccationem per insufflationem in duobus gradibus, et exsiccationem sub vacuo pro eliminatione comprehensiva contaminantium.

Capacitas Ingenieriae ad Nivellem Systematis

Societas solutiones completas praebet a developmento processus purificationis usque ad integrationem productionis, includentes coordinationem multi-roboticam, purificationem ad altam pressionem, purificationem ultrasonicam, exsiccationem sub vacuo, et systemata automatica mutationis instrumentorum.

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

• Designum ad hoc factum et automationis

• Configuratio systematis automaticae mutationis instrumentorum

• 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.

Supportus fabricationis electrici transmissiois potentiae

Cum rapida incrementatione novorum vehiculorum energiae, Big Bird Industrial solutiones specializatas purificationis praebet pro componentibus electricis transmissiois potentiae, fabricatoribus auxilians in transitione ad productionem electricam.

FAQ

Quae componentia hoc systema purgat?

Hoc systema ad integratas e-drive casas et electricas potestatis transmissio componentes, quae in fabricando novis energiae vehiculis utuntur, designatum est, inter quae sunt motorum finales tecta, reductio denticulorum casae, inversorum casae, anteriora/posteriora tecta, et motorum casae.

Quae technologiae purgationis integratae sunt?

Hoc systema integrat turbulenter purgationem (1,5 MPa), rotatoriam altam pressionem purgationem (40 MPa), duos stationes ultrasonicas purgationis, fixum punctum altam pressionem purgationem (40 MPa), duos gradus aspersionis lavandi, duos gradus exsiccationis per flatum, vacuum exsiccationem, et refrigerationem.

Quomodo hoc systema multas variantes operis peciis tractat?

Hoc systema habet automaticam QR codicum recognitionem, visionem inspectionem pro orientatione, et automaticum instrumentum mutationis systema cum instrumentorum bibliotheca pro unoquoque robotico (4 instrumenta pro unoquoque robotico), quod permittit sine interruptione mixtam productionem per 9 variantes operis peciis.

Quae contaminantia removeri possunt?

Hoc removet metallicas limas, fusoria residua, machinationis particulas, et contaminationem liquidi sectionis ab intricatis internis transitibus, aquae iaculis, et externis superficiebus.

What cleanliness levels can be achieved?

Requirimenta de puritas varia secundum specificationes componentium, typice inter 7,2 mg et 9,3 mg contaminationis residualis totalis, cum controllo stricto distributionis magnitudinis particalarum et requirimentis tensionis superficialis secundum DIN 8296 (≥ 32–36 mN/m).

Is the system customizable?

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

E-Drive Housing Cleaning in New Energy Vehicle Manufacturing

Purgatio integrata custodis e-drive est processus criticus in fabrica transmissorum electricorum pro vehiculis energiae novae. Hi custodes complexi ex aluminio combinant multas functiones—motor, inversor, et reductor—in uno componente, quare technologiae purgationis provectae necessariae sunt ad residua machinationis et contaminantes funditionis ex transitibus internis intricatis, iaculis aquae, et canalibus refrigerationis removenda. Puritas componentium e-drive directe afficit praestantiam, efficacitatem, et fidibilitatem unitatum impulsionis electricarum.

Systemata Purgationis Multi-Robotica cum Mutatione Automatica Instrumentorum

Fabricatio componentium systematis electrici potentiae postulat solutiones flexibiles et alti efficacitatis pro purgatione, quae possint tractare multas variantes operis. Systemata purgationis multi-robotica cum facultate automatica mutationis instrumentorum permittunt productionem mixtam sine ulla interventione manu facta. Fluxus operum robotici coordinati optimizant series purgationis, minuentes tempora cycli dum qualitas purgationis constans servatur in omnibus variantibus. Bibliothecae fixorum, quae quattuor fixa per robotem habent, praebent flexibilitatem pro usque ad novem variantes operis.

Purgatio ultrasonica et altae pressionis pro complicate custodiis

Complexa domus e-tractus cum geometricis internis intricatis difficultates unicas pro purgatione praebent. Purgatio ultrasonica ad cavitates internas et foramina caeca attingit quae purgatio per aspersionem conventionalem attingere non potest, dum purgatio altae pressionis (40 MPa) efficaciter residua obstinata ab superficiebus externis et ab orificiis olei removet. Purgatio ultrasonica in duobus stationibus ciclos purgationis prolongatos permittit sine effectu in totam productionis velocitatem.

Filtratio et Administratio Liquidi in Purgatione Domus E-tractus

Filtratio efficax et administratio liquidi essentialis est ad qualitatem purgationis constantem in purgatione domus e-tractus servandam. Configurationes filtrationis multistadii cum filtris rotundis (50 μm), filtris sacculorum (20 μm / 10 μm) et separatione olei operationem continuam cum monitis automaticis pro mutatione filtrorum permittunt. Accuratio filtrationis usque ad 10 μm qualitatem liquidi purgantis conservat, risus recontaminationis minuit et vitam liquidi prolongat.

Specimina Technica