Product category:
Washing and pretreatment
News Release from: MecWash Systems | Subject: Aqueous-based component cleaning at Perkins
Edited by the Manufacturingtalk Editorial
Team on 25 March 2008
Robotic, aqueous systems clean cylinder
heads
Two robot-served, aqueous-based cleaning systems are processing IC engine machined cylinder heads, removing remove coolant and swarf at levels above those originally specified.
Perkins Engines in Peterborough, UK, are now using two high quality, aqueous-based component cleaning installations from MecWash Systems The two 'Midi' units interface directly with the robotic handling systems
This article was originally published on Manufacturingtalk on 3 Jun 2008 at 8.00am (UK)
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The MecWash units are key elements in a self-contained, highly focused operation which, said Perkins, effectively enables the manufacturing cell to operate as its own profit centre.
* Cylinder heads - the facility machines cylinder heads for the Perkins Type 400D engines - in turbo and naturally-aspirated formats.
Four Heller machining centres machine the raw castings in pairs and the MecWash Midi units perform intermediate and final wash processes.
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Ultrasonics plus jetting clean parts effectively
The use of ultrasonic cleaning and dedicated jetting - all within the existing wash chamber - enables users to enhance performance, even for the most difficult cleaning tasks.
The results according to Roger Lee, NPI project manager at Perkins Engines, are excellent.
He reported: "The MecWash Midi's remove coolant and swarf which are inevitably produced by the machining operations and need to meet our specification figures of no more than 145mg per cylinder head.
The actual figure being achieved is between 10 and 20mg, which dramatically exceeds the target and makes a major contribution to maintaining the high quality levels that our customers require and expect".
The environmental gains arising from the aqueous operation of the MecWash installations are enhanced by their ability to interface directly with the Fanuc robotic system.
The robots control the full movement of the finished components from receipt through machining and washing processes and also accommodate the purpose-designed fixtures that MecWash have developed to enable the cylinder heads to be washed in the most effective way.
* Dedicated jetting facility - A dedicated jetting facility directs jets of the wash solution directly through the fixture at key areas of each component.
Not only does this allow the wash process to operate most effectively, but the pipe-work arrangement also delivers pressurised air to the same locations to optimise the subsequent drying process.
This combines with the MecWash flood and spray wash procedures - all contained in the company's rotational drum design - to produce the excellent results that Perkins are now experiencing.
MecWash director Paul Young, told manufacturingtalk: "We have also designed drag conveyors into the wash tanks to allow the machine swarf to be removed automatically, reducing operator involvement and machine downtime for cleaning.
We are delighted that each installation has met Perkins' precise requirements in terms of the cleaning and drying of complex components quickly and accurately - all within the totally automated processing operation".
Operating 24 hours a day, five days a week across three shifts and producing some 80,000 cylinder heads per year, this is a highly important part of Perkins Engines' Peterborough operation.
Structured around individual processing teams, which include production, maintenance and training, the facility demonstrates not just highly efficient manufacturing procedures but also an innovative approach to operational procedures.
The organisation of such teams effectively gives the employees 'ownership' of the process.
Young concluded: "We believe the decision to specify the MecWash Midi's within this context reflects favourably on both our equipment performance and design and also our willingness and ability to work closely with other key suppliers - of both robotics and machine tool centres - at the site.".
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