Efficient and thorough cleaning is essential in automotive component remanufacturing, especially for turbochargers. To meet the demands of high-quality restoration, the BR-450 MS was developed, a multi-stage ultrasonic cleaning machine tailored for large-scale turbocharger reconditioning.
Project Background
The client, a prominent player in the European automotive remanufacturing sector, sought a solution to streamline and optimize its cleaning process for turbocharger parts. Traditional cleaning methods often proved insufficient in removing deep-seated contaminants, such as burnt carbon and grease, from delicate turbocharger components. Additionally, they were looking for a system that could handle high volumes, improve process speed, and meet rigorous environmental standards regarding water and energy consumption.
Finishing Solution
To meet these specific demands, a highly customised ultrasonic cleaning system was designed around their BR-450 MS model. The solution featured nine separate stages, enabling comprehensive cleaning and finishing of turbochargers in a single integrated process.
Key stages included:
- Degreasing: using ultrasonic waves, the system ensures the complete removal of oil, grease, and carbon deposits.
- Pickling: this stage involves treating the parts with chemical solutions that remove rust and corrosion, preparing them for passivation.
- Passivation: this final treatment helps form a protective layer on the metal surface, ensuring longevity and resistance to further oxidation.
The system is equipped with several automated features, such as:
- Manual Hoist and Automatic Lids: for safe, easy handling of turbocharger components during the process.
- Touch Screen PLC: A programmable control unit that allows operators to set precise cleaning parameters for various parts and stages.
- Water and Detergent Management: automated systems for water filling, detergent dosing, and lubricants ensure optimal chemical usage and reduce manual intervention.
- Vapor Extraction: designed to improve worker safety, this system ensures that harmful vapors from the cleaning process are effectively contained and extracted.
The BR-450 MS also integrates energy-saving technologies, such as the ability to reuse water across different stages, making it both cost-effective and environmentally responsible.
With nine 450-liter tanks, the BR-450 MS efficiently handles large batches of parts. The system integrates automatic water filling, precise dosing of detergents and lubricants, and vapor extraction for safety. This level of automation ensures both consistent cleaning results and optimised energy usage.
Results
The BR-450 MS machine exceeded the client’s expectations, delivering high-quality restored turbochargers with 30% less energy consumption. The custom-designed baskets maximized efficiency, processing multiple parts simultaneously while maintaining consistent performance.
To learn more about ActOn’s Ultrasonic Cleaning Technology click here. For further information regarding the finishing process or to request a free Trial email our technical team.