Automotive supplier relies on automated cleaning system with gantry system
Transmission components, such as spur gears, drive shafts, connecting shafts, axle drives and main gears, are critical precision parts. Deposits and contamination on the surface would jeopardize the function of the components and the entire gearbox as such during operation. It is therefore imperative that the components are thoroughly cleaned of adhering particles, chips, lubricants and oils after the production process. In addition to the high cleanliness requirements, the focus is naturally also on high productivity and efficiency for the cleaning process. Cost pressure is forcing the automotive industry to maximize efficiency, and fully automated solutions are in demand here. One such solution has recently been implemented at a German automotive supplier. An automated basket washing system with a NiagaraDFS gantry system from BvL Oberflächentechnik GmbH was successfully commissioned for the transmission components application. The system meets all the requirements for thorough pre- and intermediate cleaning of a wide variety of components in a short cycle time.
Challenges successfully mastered
BvL Oberflächentechnik GmbH is one of the largest suppliers of aqueous-based industrial cleaning systems in Germany. As a system partner, BvL offers comprehensive customer solutions through integrated services - from small, compact washing systems to filtration and automation solutions. The decision in favor of the BvL cleaning system was influenced by several key factors. The automotive supplier was faced with the challenge of maintaining a cycle time of 15 seconds per component. The project planner benefited from the many years of experience of the cleaning system manufacturer BvL. There were already several similar reference projects for cleaning systems with automation, which formed an ideal basis for optimally tailoring this new cleaning system to the supplier's specific requirements. The specific requirements for the automated cleaning system were implemented in close cooperation between the automotive supplier's project planner and BvL during the entire project implementation.
Solution: Two-axis gantry system with gripper system
The cleaning system implemented in this way has a high degree of automation thanks to the two-axis gantry system with gripper system and, as a result, a high degree of employee decoupling. As the system can be operated with virtually no manual intervention, errors are minimized and productivity is increased. This enables the required high level of quality assurance to be achieved. The system is able to clean several baskets with a large number of different components per wash cycle in a short cycle time. In series production, the gear components are packed in stacked wire baskets and fed into the system via four loading stations. The gantry transfer unit picks up the baskets and transports them to the preparation station, where the basket stacks are collected for a cleaning batch. They are then transported to the cleaning system via a roller conveyor. All process steps - rinsing, cleaning and vacuum drying - take place in a single chamber. Thorough and all-round cleaning is carried out by a special nozzle system with a pivoting basket and subsequent flooding of the cleaning chamber.
The cleverly integrated floor roller cleaning station prevents the floor rollers from becoming dirty again after the cleaning process
Innovative Smart Cleaning technologies for greater process reliability
Another highlight is the integrated floor roller cleaning station. This station cleans the bottom rollers of the basket stacks while the baskets with the components are in the cleaning chamber. This integrated process prevents the baskets and components that have already been cleaned from becoming soiled again. The new BvL cleaning system is equipped with Smart Cleaning technologies. Maintenance prediction for the vacuum filter and consumption prediction for the bag filter enable predictive maintenance and optimized planning. The so-called Libelle Fluid Control measures the degree of contamination of the cleaning fluid and enables simple process control. This allows the operator to react quickly to changes and ensure constant component cleanliness. The insulation of the system components reduces the discharge of heat energy, which leads to a reduction in energy consumption and therefore to cost savings.
" In addition to the high cleanliness requirements, the focus is naturally also on high productivity and efficiency for the cleaning process. "
