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Cleaning parts, cleaning of complex geometric parts in a single piece flow

A software engineer is presented with a challenge. A new part is manufactured with different types and grades of steel, brass and other materials. The part is designed with a deep pit, a series of small holes, and a series of threaded blind holes superficial. Moreover, the party must conform to a certain level of cleaning by the customer.
This level of cleaning has many needs. The party must be 98% oil-free, one time, as measured by an imaging system stage. A gravimetric method also weighed Millipore, filtering pollutants and the weight of the piece should not exceed 5 mg per share. Moreover, the party can not contain particles larger than 20 microns in size.
To complete the challenge, the manufacturer must produce 2800 pieces per shift of 8 hours. The requirements for cleaning, while the rate of production will be a difficult task.
Faced with this problem, many managers assume a system of ultrasonic cleaning is the best method for cleaning the room. This method creates an intense, high-frequency vibrations that are used to attack the party and clean.
However, ultrasound can not be the best choice for this situation. Ultrasonic requires strict conditions for success. Must have created enough energy to clean the entire surface and the surface can not be protected by other parts or materials. In addition, there must be time for the ultrasonic method of work. If these conditions are not met, the process becomes less effective.
Energy
The industry standard for determining the amount of energy required is mentioned in the manual cleaning technology, cleaning shares published by the magazine in December 1998. The manual states:
"The sum of the cross section not exceeding 70% of the tank section ultrasound. In addition, the workload in a volume of mass does not exceed 30% in parts cleaning and no more than 15% of precision cleaning applications. "
Production rate
If the ultrasound is used, any problems in meeting the requirements of production rate. In order to meet the rate and use ultrasound process, a large number of parts will be loaded together, together, cleaned and transferred to the next stage together. By using this method with ultrasound, can cause problems.
The transfer of baskets used for the parties may waste energy ultrasound. All exposed surfaces are cleaned by ultrasound, including the exposed part of the transfer cart. This waste of energy needed to reach the parties. The larger the basket, the more energy wasted. Parts stacked on each other or blocked by the cart are not clean, since they are not exposed.
The parties may re-contaminated when removed from the most clean. As the cleaning is done, the oil released by the parties will be sent in the tank. Gravity oil with a slight increase in surface water. When the process is complete, the basket was lifted out of the water. Of course, we pass through this layer of oil to the parties the opportunity to recover a little 'oil during the movement.
Finally, the research cited by the cleaning of parts of the magazine in December 1998, shows that particles smaller than 25 microns in size are not effectively removed by ultrasonic cleaning, which is unacceptable according to the needs of our project.
Solution
The transport index is an effective alternative to ultrasonic cleaning for the case presented. The tape consists of the following steps:
1. Manually or robotically loaded into a nest or accessory intended to be held in place for the transfer from one stage to another.
2nd The party-oriented index to the extent that a tire on a manifold with rubber gasket is energy, and moved to stand to swallow the party.
3rd Heated, chemically mixed solution by the floods which is pumped through the collector. This solution will be pumped into the bottom of the device.
4th The manifold gasket is lifted, while spraying the solution on the workpiece. The sheer strength of liquid combined with the temperature and chemical to remove the particles of oil and all cracks, holes, threads and surfaces.
5th Part is indexed to the next stage of corrosion protection of fluids, if necessary.
6. Part is indexed to the next stage in which the void is a part dry. Here is the submerged part of a collector with rubber gasket that creates a vacuum that allows the mechanism to lower the temperature of boiling water so that all the liquid evaporates before the collector is released.
7th So is indexed to the phase in which the robot or to download an operator is able to eliminate a clean, dry part that is neither too hot or too cold.
The sequence of operations may be the time to meet production requirements. This system also offers increased flexibility with respect to the method of ultrasound. Vacuum pumps, dryers, harvesters, and activities of all the tires can be sized to take the necessary action to clean the part properly and the moisture evaporates. Devices such as cleaning fluid management, filtering, and in the process of treatment options can be added to the system if necessary.
This system is able to effectively meet all the needs of production and clearance in the challenge presented, making it more attractive option that the method of ultrasound.

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