For each sector there are different production processes that require long processing times. In this article we will see how we have customized the Washer 900 E POWER, based on the washing needs of our customer in the engineering sector, to reduce production times while increasing safety and productivity. 

The Client

The company has been operating for years in the engineering sector; precisely, it deals with the design and production of machines for handling and unloading in various sectors. The solutions it offers allow you to increase productivity and reduce the risk of accidents at work.

We are talking about complete mechatronic systems that help people carry out the most complex tasks in total safety, such as: earthmoving, moving bulky loads, agricultural work and transport.

The customer decided to contact us to obtain a personalized product, based on his washing needs, in order to optimize the production process.

The Goal

The construction of handling machines requires maximum precision in each step. For this reason, the production process requires medium-long lead times to guarantee an efficient and safe product.

The customer's request was to combine washing and drying in a single solution, reducing manual handling of the pieces and production time to a minimum.

Another request was to program the washing cycles based on the type and number of pieces, to activate the parts washer automatically and control the entire process. In this way, it is also possible to know the required times and optimize the subsequent phases until the finished product is obtained.

In short:

• Combined washing and drying system;
• Reduce production process times;
• Program the washing cycles.

The Solution

First of all, we analysed each phase of the production system on site. In this way, it was possible to verify the type of washing and drying required, the size and the daily quantity. This is an important step in offering a complete service in line with the needs of the company, so that it can also guarantee its customers a satisfactory product.

We have analysed the production potential of the parts washing machine and identified the weak points of the process, in order to intervene and refine the system.

To create a combined washing and drying system, we selected a standard machine, the Washer 900 E POWER, from which to start the design, comparing the information obtained both during on-site verification and during some technical meetings. We have drawn up a rough estimate, to understand the company's availability, considering that some empirical tests would be needed to test the drying process. It was immediately evident that the classic pneumatic drying system, using laser-drilled arms, was not powerful and precise enough. Therefore, we searched the market for new drying elements: only air blades were suitable to meet the customer's cleaning needs and we focused on those.

During subsequent tests we improved the washing system by changing the heights and lengths of the washing arms. Furthermore, we have integrated the following components into the Washer 900:

• Standard connection system to the company water network;
• Dispenser;
• Standard vapor extraction system.

A control panel with programmable PLC has been added to the Washer 900 to manage different washing cycles. Furthermore, we have implemented safety by installing, on the front of the parts washer, a control panel with a two-hand opening and closing system and with automatic starting. Then, the department manager schedules the washing and the end operators only need to press the "start" button to operate the machine.

The main difficulty of this process was drying. The pieces to be washed for compliance have many "blind" spots, so the drying system had to be powerful and precise. Thanks to our experiences and our team of experts we managed to solve all the challenges within the set times. 

The Results

The company is now equipped with an efficient combined system that has speeded up and improved the manufacturing process of their products. Integrated automatic systems have increased daily productivity and eliminated some previously time-consuming manual processing steps.

After a trial period, the owner was satisfied with the result and decided to buy a second machine. Now, we plan to build another two customized machines for two different types of product.

We had the opportunity to design and test new options - drying system, washing cycle programming and process control - available to all our customers.