This article will take an in-depth look at aqueous part washers.
The article will bring more detail on topics such as:
This chapter will explore aqueous part washers, including their design and functionality.
An aqueous part washer is a machine, either automated or semi-automated, designed to clean and remove stubborn grease from both large and small parts. It also dries the parts, preparing them for distribution or further surface treatments.
Washing is essential because, during manufacturing, machines are often forged and assembled with parts coated in chemicals, oils, and other residual substances from the fabrication process.
In the basic design of aqueous part washers, one must first consider the size, shape, and configuration of the parts that need cleaning. Other special aspects to consider are weight angles of parts, surface area, and blind holes. Manufacturers also consider CNC programming, front or back loading baskets, rack systems, trays, conveyor belts, and rotary tables for some types of washers.
Most parts washers are aqueous, utilizing water-based solvents to soak, boil, or blast dirty parts. Key components of these washers include a water heater, pumps, filtration system, brushes, scrubbers, and a cabinet or enclosed space.
The water heater is a crucial component of the cleaning unit. It can be powered by gas, steam, or electricity, and is responsible for raising the temperature of the cleaning solution, which helps to reduce the cleaning time. Increased temperature accelerates the chemical reactions of the solvents, detergents, and other chemicals used in the process.
The filtration system filters the water flowing into the system. Upon activation, the cleaning solution or solvent will flow from the cleaning tank and into the storage tank. It's driven through two filters when it flows from the cleaning tank to the storage tank. The first filter consists of a large grid that can capture the large particles before entering the tank. The second filter is designed to hold small particles that would have escaped the larger filter.
The pump is responsible for circulating the solvent, water, or detergent within the system. It continuously draws the cleaning solutions from the storage tank and delivers them to the cleaning tank. Designed to operate at high temperatures and at a rapid flow rate, the pump ensures effective cleaning. Insufficient performance in these areas can lead to inadequate dirt removal.
The scrubbers in parts washers typically consist of either a sprayer or a set of brushes. The pump circulates the cleaning solution from the tank to these scrubbers, facilitating the cleaning process.
Washer cabinets come in various sizes and capacities, designed to handle different cleaning needs. The cleaning process involves applying high-pressure aqueous solutions either within the cabinet or along a conveyor belt. The water pressure must be adequate to effectively remove contaminants. Cabinets are constructed robustly to endure the stress from high-pressure liquids and resist damage from corrosive substances.
Maintaining the correct water level in the storage tank is crucial. If the water level falls too low, the exposed heaters could be damaged. To prevent this, an automatic low water shut-off valve deactivates the parts washer until the water level is restored to the required minimum.
The operation of a parts washer involves timed intervals. Initially, parts are placed on the turntable inside the washer, and the door is secured with latches. The cleaning cycle is then started. During this cycle, a high-temperature and high-pressure solution of water and detergent is used to blast away dirt and contaminants from the parts.
The washer utilizes a closed-loop waste minimization system. The following factors determine its operation:
The effectiveness of the washer's cleaning capability is primarily influenced by its power. Higher power levels enhance the washer's ability to blast and remove dirt from parts. This power is determined by the pressure and flow rate of the cleaning solution, which together create the physical force needed to dislodge residues and soils.
Increasing the temperature of the cleaning solution makes oil and grease more fluid and reduces their viscosity. Grease, often a major binder for soil, becomes more manageable as the temperature rises. For instance, heating the solution to around 160 °F (71 °C) improves cleaning efficiency by breaking down grease more effectively.
Additionally, higher temperatures accelerate the chemical reactions in cleaning solutions. Generally, a temperature increase of 54 °F (12.22 °C) can double the rate of these reactions, leading to faster and more thorough cleaning results.
The composition of the chemical solution is crucial for the industrial strength of the washer. Chemicals enhance the cleaning power of the solvent, with some possessing abrasive and corrosive properties to aggressively remove stains and grease. Alkaline chemicals are commonly used to minimize environmental impact.
Aqueous part washers come in various types, primarily categorized by their construction and operational methods.
Spray washers use spray cabinets that clean parts by spraying a jet of heated solutions at moderate to high pressures inside an enclosed cabinet. The cabinets have a range of sizes depending on the parts that need to be cleaned, ranging from small to very large-sized cabinets. The spraying nozzles can clean away the heavy and difficult residues of soil, grease, oil, buffing substances, heat debris, and other contaminants.
In this type of part washer, parts are loaded through a front cabinet door into a perforated basket. Inside the cabinet, the basket rotates periodically while the parts are exposed to a high-pressure spray of cleaning chemicals, detergents, and water. This design allows for the efficient and convenient cleaning of multiple parts simultaneously.
A sink-top aqueous part washer is a straightforward and commonly used type of washer, essentially consisting of a sink mounted atop a drum. It is designed for cleaning individual or a small number of parts. This washer includes a drum that holds the solvent or water, along with a pump and brushes to manage and direct the cleaning solution. The sink-top design allows for hands-on cleaning with controlled application of the solvent.
For certain complex equipment parts, intensive cleaning is necessary because some contaminants and oxidation are resistant to standard pressure sprays or immersion methods. Ultrasonic cleaning systems address this by using ultrasound at frequencies ranging from 20 to 400 kHz, combined with a specialized cleaning solution. An ultrasonic system typically comprises three main components: a tank to hold the cleaning liquid and the dirty parts, a generator that converts the line voltage into ultrasonic waves, and transducers that produce the ultrasonic vibrations in the tank.
Transducers play a crucial role in converting ultrasonic electrical signals into kinetic and mechanical energy. During the cleaning process, high-frequency sound waves produce cavitation bubbles that agitate the cleaning liquid, generating heat energy in the process. This agitation energy penetrates deep into small holes, thin cracks, and crevices, effectively removing stubborn contaminants. Ultrasonic parts washers, which are often bench-top units, can vary greatly in size and may occupy substantial amounts of space.
Immersion part washers feature robust and simple tanks equipped with a pneumatically powered, reciprocating mechanism to agitate parts within a water-based fluid. These washers rely on a combination of agitation and oscillation to effectively clean parts immersed in a bath of cleaning solvents.
First, the parts are fully immersed in the solvent. Once the parts are thoroughly coated, an oscillatory vibrating action is applied to create turbulence within the solution, ensuring a thorough cleaning of the parts.
Conveyor parts washing systems utilize an enclosed and automated transport mechanism. These washers feature various belt options, including continuous flat wire, interlocking plastic, wire mesh, roller, and chain belts. The guide rails, which can be either fixed or adjustable, secure the components and contents on the belt during the washing process.
The mechanism in conveyor parts washing systems moves baskets or fixtures through each stage of the cleaning process. The design of the mechanism varies depending on the requirements of each cleaning stage. Conveyor parts washers are equipped with numerous features to streamline the washing process, including robotic and mechanized feeding systems. Some models offer adjustable settings for steel belt speeds, moisture blow-off, precise filtration units, heaters, and exhaust ducts. These systems ensure a continuous inline flow with distinct zones for high-temperature washing, rinsing, and air drying. Custom specifications can be tailored based on the parameters of the parts being cleaned.
Conveyor continuous flow systems are designed to maintain a constant throughput of parts with minimal direct handling. The key differences among systems often relate to whether they have fixed or variable speeds and the types of products they can process. Belt conveyor part washers are noted for their high efficiency and rapid processing speeds.
Rotary drum washers use a rotating drum equipped with an internal helix designed to advance and tumble parts through one or more stages. These washers are particularly effective for cleaning very small parts in high volumes. Similar to conveyor parts washers, rotary drum washers automate the processes of cleaning, rinsing, and drying, utilizing high-pressure sprayers for the cleaning phase. Additionally, an immersion agitation mechanism enhances the cleaning process by thoroughly reaching into tubes and hollows.
The drum sizes usually vary from 12 to up to 72 inches (30.48 to 182.88 cm), and the pitch and height of the inside helix can be altered or custom-made so that it meets the working requirements of part geometry and the optimum feed speeds. The rotary drum washers also allow for spray, immersion, or both, including washing, rinsing, drying, oil separation, and other advanced features.
Aqueous part washers offer various applications and benefits, including:
Aqueous part washers are utilized across a broad range of applications, from industrial settings to everyday commercial activities. If a machine fails, it can disrupt the entire system, potentially damaging products and harming the brand's reputation, which may impact future sales. In particular, part washers are extensively used in the automotive industry for degreasing and cleaning parts and equipment affected by grease and oil.
Parts are cleaned using aqueous part washers to ensure proper reconditioning and servicing, enabling continued, efficient operation. In addition to their use in the aerospace sector, part washers are also employed to clean aeronautical components, providing thorough and reliable cleaning for sustained performance. They are particularly effective for cleaning metal pipes, handling any size, shape, or material with consistent reliability.
Many chemicals used in parts cleaning can be harmful and pose significant health risks. Examples include trichloroethylene, perchloroethylene, and n-propyl bromide, all of which release volatile organic compounds (VOCs). These substances are highly flammable and can lead to severe health issues, such as headaches, dizziness, respiratory problems, and exacerbated allergy symptoms. Part washers are crucial in reducing direct human exposure to these hazardous chemicals. They primarily use water, heat energy, and alkaline detergents, which generally pose fewer health risks.
The chemicals used in parts cleaning not only pose risks to human and animal health but also to the environment. Solvent cleaners contribute to land and air pollution, which can be significantly reduced by using less harmful aqueous part washers. These washers utilize environmentally friendly materials, and residues are carefully managed before disposal.
Facility owners should prioritize worker safety alongside business needs. Aqueous part washers offer short run times, resulting in lower electricity costs and reduced labor requirements. They are highly economical due to their efficient mechanical performance.
In the manufacturing process, maintaining clean and well-maintained industrial machines is essential for uninterrupted operations. Regular upkeep ensures that equipment remains in optimal condition with minimal downtime. Aqueous part washers and other cleaning equipment are crucial for ensuring the safety, longevity, and quality of machinery and, consequently, the final products. The following sections detail how aqueous part washers benefit the manufacturing industry.
Incorrect components can compromise the entire product and damage the brand's reputation. They can also affect machine performance, leading to breakdowns and interruptions. Parts cleaners help remove residues and ensure smooth machine operation. Regular maintenance prevents surface damage, a major issue for industrial machines. Utilizing stock resource baskets and ultrasonic baskets can help prevent part damage.
Scrap production is an inevitable part of any manufacturing process and contributes to increased production costs. However, aligning maintenance with parts washing can significantly reduce scrap. Addressing part damages and removing debris and grease helps minimize waste and improve efficiency.
Production delays can severely impact output, sales, and brand reputation. Using parts cleaning machines helps prevent unforeseen machinery breakdowns, thereby reducing the likelihood of production delays.
Machines that lack regular maintenance are prone to frequent breakdowns, leading to higher repair and maintenance costs. Investing in reliable equipment like conveyor parts cleaners, part cleaning systems, and industrial cleaners can reduce the need for frequent repairs and replacements, offering long-term cost savings.
Aqueous part cleaners involve a moderate to high initial investment. Setting up these systems requires technical expertise to ensure reliability and efficiency. They use electrical energy for heating and energy conversion, making them more expensive compared to traditional solvent units. Additionally, aqueous part washers can be vulnerable to corrosion from oxygen or water. To mitigate rusting, rust inhibitors and additional drying mechanisms should be used to prevent moisture accumulation. Some stains and residues can be particularly stubborn and challenging to clean.
Chemical residues can be difficult to remove, even with ultrasonic part washers. Aqueous part washers require significant attention and intensive maintenance to prevent blockages, clogs, or damage caused by residual dirt from cleaned parts. Additionally, some part washers have a compact design that limits their ability to clean very large components. Their cleaning compartments may be too small to accommodate larger parts effectively.
Aqueous part washers operate similarly to other industrial part washers, with the primary goal of removing dust, oil, and grease from machine surfaces. However, these devices use different methods compared to other types of washers. Aqueous cleaners employ detergents, water, corrosive agents, and heat energy to remove debris from mechanical parts. While they are generally safe to operate, these washers can become hazardous if contaminated beyond their operational limits. Excessive contamination can lead to flash points exceeding 140 °F (60 °C), increasing the risk of flammability during the cleaning process.
In addition to increased heat output, aqueous cleaning systems can present other serious safety concerns. Without proper monitoring, these systems can reach pH levels below 2.0 (highly acidic) or above 12.5 (highly alkaline), both of which can have detrimental effects on the environment.
Aqueous cleaning machines use water to clean and rinse machine parts. Businesses must manage their water usage to comply with regulations and control costs. Facilities using aqueous cleaning systems should implement strategies to minimize water consumption while maintaining effective cleaning processes.
To protect both final products and employees during production and cleaning, operators must monitor the hazard levels of cleaning solutions. While some part washing systems are marketed as non-toxic or non-hazardous, these solutions can become hazardous over time. As they accumulate metal-bearing oils and grease, their toxicity and potency can increase. The following techniques can help control toxin levels in the cleaning solution:
Another critical factor in part washing is the choice of chemical or detergent used. The selection of detergent depends on the nature of the parts being cleaned and the cleaning method employed, whether ultrasonic or spray.
Parts cleaning often involves hazardous and toxic detergents and chemicals. Therefore, it is crucial to monitor the workplace environment to ensure proper control over these chemicals to prevent illness and injuries.
Detergents and chemicals used in parts cleaning generally include:
Cleaning parts effectively requires materials designed to remove grease, oil, grime, chemical residues, and soil from high volumes of parts. Due to growing environmental concerns, manufacturers are increasingly using biodegradable ingredients in their cleaning solutions.
Oil-eating detergents are highly effective for cleaning industrial parts and can serve as acid-free degreasers.
Water-based cleaning chemicals typically have a neutral pH and are non-toxic, non-flammable, and non-irritating. They are also suitable for use in bioremediation systems.
Detergents for aqueous parts cleaners are formulated for use in jet sprayers and power stream washers. To maximize efficiency, these detergent solvents include defoamers that rise to the surface of the cleaning solution to prevent foaming.
Numerous types of washing solutions are designed to be used in ultrasonic parts cleaners. The different types include acidic chemicals, alkaline chemicals, high caustic solutions, deionized water, enzymatic chemicals, neutral solution, and mildly alkaline chemicals.
Ultrasonic washing solutions are classified as either demulsifying or emulsifying. Demulsifying solutions are used to remove oily contaminants and should be drained from the tank promptly after cleaning. Emulsifying solutions, in contrast, suspend contaminants within the tank. If used over multiple cleaning cycles, debris may adhere to the parts upon removal.
Effective parts cleaning often requires strong abrasive chemicals for superior performance. Powerful cleaning agents, such as Trichloroethylene, Sodium Hydroxide, Butyl Cellosolve, Acetone, Toluene, and Benzene, are commonly used. Each of these chemicals serves a specific purpose:
Trichloroethylene is a water-like solvent used in various cleaning solutions. Sodium Hydroxide is a caustic agent that can dissolve grease, oil, fatty acids, and protein deposits. Butyl Cellosolve is frequently used in both industrial and household cleaners. Acetone is a versatile cleaner often used to prepare metals for painting.
Toluene, a solvent less potent than acetone and butanone, is primarily used in paint thinners and can dissolve adhesives, rubbers, and sealants. Bacteria, employed in part cleaners, offer a natural method of stain and soil removal through bioremediation. Benzene is widely used in manufacturing but requires careful handling due to its hazardous effects.
In summation, aqueous part washers are a form of machinery used to clean small to medium parts of industrial machines through the use of water-based solvents and temperature controls.
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