Large Crankshaft High-Pressure Cleaning System

The Big Bird Industrial Large Crankshaft High-Pressure Cleaning System is developed for final cleaning of large crankshafts used in heavy-duty diesel engine manufacturing. The system removes machining chips, grinding particles, and cutting fluid residues from oil galleries, flange holes, threaded holes, and all external surfaces before final assembly.

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

Workpiece Applications

The system accommodates multiple large crankshaft variants:

All workpieces are large crankshafts for heavy-duty diesel engine applications. The system accommodates workpieces from 1,500 to 4,000 mm in length and up to 2,000 kg in weight, with maximum swing diameter up to 600 mm.

Automatic Mixed-Model Production

The system supports automatic mixed-model production with:

QR Code Recognition

A handheld QR code scanner reads workpiece identification upon loading. The system automatically selects the appropriate cleaning program based on the QR code information. The system supports 10 preset programs with capacity for 90 additional programs (PLC and HMI ready). Data is stored for over 1 year with MES interface capability.

Program Storage

Over 100 product programs can be stored, with import/export functionality. Program names support letters, numbers, and Chinese characters up to 50 characters.

Manual Changeover

V-blocks, U-blocks, and flange-side locating pins are manually changed when switching between workpiece variants. A scale on the guide rail marks the movable tailstock position for each workpiece type. All tooling features quick-change design without tools.

Workpiece Verification

Workpiece presence and type detection ensures that only verified workpieces enter the cleaning chamber.

Multi-Stage Cleaning Process

The system combines multiple cleaning technologies in a 5-stage automated sequence:

Stage 1: Loading (1ST) — Manual

The operator lifts the workpiece onto the loading pallet V-blocks and U-blocks. V-blocks support the main bearing journals, and U-blocks support the crankpin journals. Contact materials are non-ferrous or non-metallic to prevent scoring.

The operator locks the left and right locating bases, then manually advances the tailstock center to clamp the workpiece using a handwheel. The operator presses the two-hand start button, bottom locating cylinders retract, and the motor-driven conveyor automatically transfers the workpiece and pallet into the cleaning chamber.

The operator manually cleans and blow-dries the workpiece center holes and flange locating pin holes using the supplied water gun and air gun at the loading station.

Stage 2: High-Pressure & Spray Cleaning (2ST) — 2 MPa & 45 MPa

The workpiece and pallet are positioned, and locating cylinders extend for pallet positioning. A servo motor drives the workpiece rotation via a drive shaft with pin engagement.

A 6-axis robot holding a high-pressure nozzle moves horizontally via servo drive to perform high-pressure cleaning of fillet radius and transition area oxide scale. Simultaneously, a C-type cleaning nozzle tube performs scanning spray cleaning of the workpiece surface and end faces. The C-type nozzle tube moves along the Z-axis via motor drive with adjustable speed. The workpiece rotates in both directions with adjustable speed until all surfaces are cleaned.

After spray cleaning, the robot performs fixed-point high-pressure cleaning of oil galleries and flange surfaces. Cleaning sequence: connecting rod straight oil holes → angled oil holes → main bearing straight oil holes. Net cleaning time is adjustable for each oil hole.

After cleaning, blow-drying nozzles dry the workpiece surface while the workpiece rotates for tilt-drainage.

Stage 3: Plug-Pin Cleaning & Rinsing (3ST) — 4 MPa & 45 MPa

The workpiece is positioned and rotated as in Stage 2. The C-type rinsing nozzle tube performs scanning spray rinsing of the workpiece surface and end faces.

The robot holds plug-pin nozzles to seal both sides of main bearing oil galleries for high-flow flushing. The plug-pin nozzles are driven by cylinders to enable through-hole rinsing. Spring-loaded pads on the plug-pin cleaning station provide compatibility for components with similar diameters.

After rinsing, the workpiece is tilted for drain-off. The robot performs blow-drying of all holes with tilt-drainage during the process.

Stage 4: Blow-Drying (4ST)

The workpiece and pallet are positioned. The internal blow-drying nozzle tube moves via servo motor to perform scanning blow-drying of the workpiece surface. The blow-drying nozzle tube moves along the Z-axis via motor drive.

Stage 5: Unloading (5ST)

After blow-drying, locating cylinders retract, the station door opens, and the motor-driven conveyor transfers the workpiece and pallet to the unloading station. The operator removes the workpiece. Empty pallets are returned via the lower-layer conveyor for pallet circulation.

High-Pressure Cleaning Technology

The system features exceptional high-pressure cleaning capability:

This extreme high-pressure capability enables effective removal of stubborn oxide scale, grinding particles, and metal chips from deep oil galleries and complex internal passages.

Technical Cleanliness Control

For heavy-duty diesel engine manufacturing, cleanliness of crankshaft oil galleries and critical surfaces directly affects engine reliability and performance.

The system is designed to meet strict cleanliness requirements:

Advanced Filtration Management

The system employs a three-stage filtration system:

Filtration Features:

• Filter blockage alarm displayed on HMI

• Non-stop filter change capability

• Filter bag brand: Oerfu

• Filter validation: 100 mL cleaning fluid → particles <100 μm, weight <4 mg (within normal filter bag service life)

Robot System

The system features an IP67-rated robot:

Intelligent Manufacturing Integration

The system supports Industry 4.0 requirements through comprehensive data connectivity:

MES Communication

• QR code-based workpiece tracking

• Production data acquisition

• Process data recording (cleaning temperature, pressure, cycle time)

• Data export capability

Operator Interface

• Siemens TP1200 touch screen

• Chinese language interface

• Workpiece information display

• Cleaning program selection and direct call

• Cleaning progress monitoring

• Temperature and pressure display

• Fault diagnosis and alarm display

Data Acquisition

• Equipment fault monitoring

• Production count and cycle time recording

• Equipment uptime tracking

Application Case

Complete Cleaning Solution

Big Bird Industrial provides comprehensive engineering solutions including:

Process Development

• Component analysis for large crankshafts

• Cleaning process design for heavy-duty engine components

• Cleanliness requirement evaluation

Equipment Integration

• High-pressure cleaning systems (45 MPa)

• Spray cleaning technology

• Plug-pin cleaning with oil gallery sealing

• Robotic blow-drying systems

• Multi-stage filtration management

• Conveyor and pallet circulation systems

Smart Manufacturing Connection

• MES interface

• QR code traceability

• Production data acquisition

Why Choose Big Bird Industrial

Heavy-Duty Crankshaft Experience

Big Bird Industrial specializes in precision cleaning solutions for heavy-duty powertrain components, with proven experience in large crankshaft cleaning for diesel engine manufacturing with workpieces up to 4,000 mm and 2,000 kg.

High-Pressure Cleaning Technology

The system delivers high-pressure cleaning up to 45 MPa (max 48 MPa) — the highest pressure capability among all Big Bird Industrial systems — ensuring effective removal of stubborn oxide scale, grinding particles, and metal chips from deep oil galleries and complex internal passages.

Plug-Pin Cleaning with Oil Gallery Sealing

The system features plug-pin cleaning technology that seals both sides of main bearing oil galleries for high-flow through-hole flushing, ensuring thorough cleaning of internal oil passages that conventional spray cleaning cannot reach.

System-Level Engineering Capability

The company provides complete solutions from cleaning process development to production integration, including high-pressure cleaning, plug-pin cleaning, robotic blow-drying, and intelligent traceability.

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.

Large Component Handling Expertise

The system is specifically designed for large components up to 4,000 mm in length and 2,000 kg in weight, demonstrating Big Bird Industrial's capability in heavy-duty engine component cleaning.

FAQ

What components does this cleaning system process?

This system is designed for large crankshafts used in heavy-duty diesel engine manufacturing — 10 variants from 1,500 to 4,000 mm in length and up to 2,000 kg in weight.

What cleaning pressure is available?

The system delivers high-pressure cleaning up to 45 MPa (max adjustable 48 MPa) — the highest pressure capability among Big Bird Industrial systems for effective oil gallery and surface cleaning.

How are oil galleries cleaned?

The system combines high-pressure fixed-point cleaning (45 MPa) and plug-pin cleaning with oil gallery sealing for high-flow through-hole flushing of all main bearing oil galleries and connecting rod oil holes.

How are different crankshaft variants handled?

The system features manual changeover with V-blocks, U-blocks, and locating pins. A scale on the guide rail marks the movable tailstock position for each workpiece type. All tooling features quick-change design without tools.

What cleanliness levels can be achieved?

Total residual contamination ≤80–90 mg; oil gallery contamination ≤10 mg (select variants); maximum particle size ≤0.5–0.6 mm; with strict oil gallery particle count limits per GB/T 3821-2005.

Does it support MES integration?

Yes. QR code scanning, MES communication, and production data acquisition are fully supported.

What is the typical cycle time?

The system delivers ≤30 minutes per piece (excluding loading/unloading), with cycle time customizable per production line requirements.

Large Crankshaft Cleaning in Heavy-Duty Diesel Engine Manufacturing

Large crankshaft cleaning is a critical process between machining and assembly in heavy-duty diesel engine manufacturing. Crankshafts up to 4,000 mm in length and 2,000 kg in weight require advanced cleaning technologies to remove oxide scale, grinding particles, metal chips, and cutting fluid residues from complex oil galleries, flange holes, and all external surfaces. High-pressure cleaning systems deliver the cleaning power necessary for thorough removal of stubborn contaminants from these large, critical components.

High-Pressure Cleaning (45 MPa) for Large Crankshaft Components

Large crankshafts with deep oil galleries and complex geometries require extreme cleaning pressure for effective contaminant removal. High-pressure cleaning systems delivering 45 MPa (max 48 MPa) effectively remove stubborn oxide scale, grinding particles, and metal chips from oil galleries and critical surfaces. Variable frequency drive control allows pressure adjustment for different component requirements and contamination levels.

Plug-Pin Cleaning Technology for Oil Gallery Through-Flushing

Oil gallery cleaning in large crankshafts requires specialized plug-pin technology for effective through-hole flushing. Plug-pin nozzles seal both sides of main bearing oil galleries, enabling high-flow flushing that reaches the entire internal passage. This technology ensures thorough removal of contaminants from oil galleries that conventional spray cleaning cannot reach.

Filtration and Fluid Management in Large Component Cleaning

Effective filtration is essential for maintaining cleaning quality in large component high-pressure cleaning. Three-stage filtration systems with magnetic separators and bag 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 10 μm ensures cleaning fluid quality is maintained for consistent cleaning results.

Technical Specifications