Dürr Ecoclean Cleaning systems for automotive industry

Different approaches towards cleaning of cylinder heads and blocks

The quality and operational reliability of automobiles and commercial ve-hicles are fundamentally dependent on the cleanness of their individual components. This requires optimum solutions in terms of technology and economy for manufacturers of industrial cleaning systems. Dürr Ecoclean’s division “Cleaning Systems Automotive” concentrates on standardi-sed and customised, flexible solutions for the automotive industry and its suppliers. Being a proven supplier for nearly all OEMs, Dürr Ecoclean develops and produces aqueous cleaning and deburring systems for large and medium-sizedserial parts, such as those from the power train, especially engine and gear boxcomponents. The decision for a cleaning system is taken depending on the special demands of the customer, like, e.g., part dimensions, required cleaning quality, throughput, cost-effectiveness or flexibility with regard to possible changes of workpiece or production. Two possible solutions will presented hereafter – one being a high-tech solution offering maximum flexibility, the other an all-round package with standard options for limited investments.

Dürr Ecoclean’s EcoCFlex
– the flexible approach
The technology of the EcoCFlex cleaning machine combines proven cleaning methods with the flexibility of a 6-axis robot, fully integrated into a treatment module. This design permits fast process optimisation or adjustment, involving quick, minimum-effort workpiece changes or integration of new workpiece types.

Individual or palletised workpieces are picked up by the robot at a defined point outside the system and transferred into the multifunctional chamber for cleaning. Once the part is loaded, everything takes place in the same location: cleaning, air drying, and optional vacuum drying. The robot movements can be precisely adapted for specialised cleaning requirements via a workpiece specific programme.

Robots are ideally suited to the cleaning of different industrial parts, especially those with complex geometric shapes. Unlike transfer installations where the parts lie on a transport system and are indexed from one treatment station to the next, the robotic cleaning system manipulates the workpieces for optimal cleaning according to their geometry. The realignment of the machine for varying workpieces is only one of the cleaning process adjustments, which can be made with little effort. By modifying its programme, the EcoCFlex robot is able to accommodate various part types. The robot’s movements are timed to achieve the best possible cleaning results. The flexibility to accommodate many parts is vital when taking into account the scale and complexity of powertrain components. One highlight of this system is the new robot gripper. Whereas many grippers are designed according to the workpiece with the associated costs of adaptation, the EcoCFlex gripper can be easily adjusted to suit different workpieces and meets all of the requirements of a state-of-the-art cleaning system. In addition, the system offers high levels of safety, operates under the most difficult wet chemical environmental conditions and can handle workpieces of up to 300 kg.

Technologically the system combines proven cleaning processes, most of which takes place in the central multi-functional chamber. A spray system is installed for powerful injection flood washing (power IFW), targeted rinsing and optional high-pressure deburring. Additional equipment for further cleaning processes can be installed at any time. Depending on cleaning requirements, it is possible to mount additional treatment processes on the outside of the multifunctional chamber. General pre-drying of the industrial parts is accomplished by intense air drying. An optional vacuum drying system ensures 100% drying of all the parts. The EcoCFlex can be incorporated in different sections of the production process. Taken for intermediate or final washing processes, customisation of the cleaning process can be achieved quickly and with little effort. In summary it can be said that the system meets the demands on top quality cleaning and maximum flexibility with a reduced footprint. In addition, Dürr Ecoclean has decreased the electricity and water consumption as well as the total life cycle costs.

The all-round package with standard options – the chamber type cleaning machine

The technology embodied in the Ecoclean chamber type cleaning machine reflects an extensive experience with cleaning equipment combining high turbulence injection flood washing and blow-off drying in a single chamber. With numerous of such systems sold worldwide, Dürr Ecoclean has amply demonstrated the performance of this technology. Over long series of trials conducted at Dürr Ecoclean’s Technical Center, this process has been refined to perfection. The combination of spray cleaning and injection flood washing ensures that both outside surfaces and hard-to reach bores and cavities in the components are thoroughly cleaned. The subsequent high-speed air blowing cycle dries off most of the adhering cleaning medium.

The workpiece is flushed with a flow of the cleaning medium. The workpiece is flushed with a flow of the cleaning media. Jets with optimum combination of pressure, volume flow rate and temperature of cleaning media within the specified cycle times are imparted on to the workpiece. With Dürr Ecoclean’s technology it is possible to have dedicated jets for special areas tooled up in the same chamber. The working chamber is flooded with cleaning medium and immense high volume flushing currents are generated in all the critical areas - a must for cylinder heads and crankcases. The resulting flow movements ensure that the product is thoroughly cleaned both externally and in hidden recesses and cavities. The drying takes place by virtue of blow off system, integrated with powerful air fan. For the work pieces of simple geometry, this generally suffices to achieve complete drying. The work pieces can be moved in various ways inside the working chamber. Depending on the work piece type and cleaning requirement, several movement parameters (swiveling through different angles, complete rotation, no movement) can be preset. The sequence and duration of the various cleaning and drying processes can be individually adjusted for optimum performance. The extremely compact foot print of 2900 x 2500 x 3470 mm (height includes mist extractor unit) adds to the savings in terms of floor space and peripheral connection over the life cycle of the machine. Single working chamber for all the process with good access make it a very maintenance friendly machine good access to all the parts in the machine. The machine is available with 3 different standard sizes to handle workpieces up to 500 kg.

Similar to EcoCFlex, this machine can also be incorporated in different sections of the production process for intermediate cleaning or for final cleaning. Being manufactured in its Asian production, Dürr Ecoclean is able to offer the European technology to a very attractive price level.