Technical data:

• What was needed: To automatically wash complex parts after painting in the automotive industry: this task is performed by the carousel washing system from the Polish manufacturer Noyen
• Requirements: 100% lubrication-free and maintenance-free, withstands high humidity and high temperatures, lightweight, robust, accurate positioning, easy to retrofit
• Products used: drylin® linear module SHT-20, with integrated dryspin® lead screw and lead screw nut
   
• Success for the customer: An important design goal was to create the possibility of simple and ergonomic manual loading. The large number of references required not only suitable tools, but also actuator repositioning between references. This required a lockable, easy-to-operate, sliding mechanism. The solution had to be both lightweight, as it is built into a carousel, and robust. It was therefore decided to implement a new design with bearings.

Problem

NOYEN Expert C works in the final assembly line of parts that will be one of the most important components of the future vehicle. The washing process takes place after the parts are painted and before they are packed. Since most of the products manufactured in the factory have to pass through this production step, the machine had to meet the requirements for easy changeover and handling of all types of manufactured parts. Adapting the machine to handle dozens of different product references while maintaining the condition of easy changeover, as well as developing and implementing an innovative method for washing components for which cleanliness standards did not previously exist, were the major design challenges. Combined with the need to adjust the equipment to different references, special tools have been developed to allow the handling of any type of workpiece, its correct orientation during the washing process and a high repeatability of the pick-up and set-down positions required for automation processes. An important goal of the design was to create the possibility of easy and ergonomic manual loading. The large number of references required not only suitable tools, but also actuator repositioning between references. This required a lockable, easy-to-operate, sliding mechanism. The solution had to be both lightweight, as it is built into a carousel, which requires weight reduction, and also robust. It was therefore decided to implement a new design with bearings. Since the system is located inside the washing machine, the work of the components takes place at high temperatures and high humidity. In addition, the system is subject to impact loads from the robot or positioning inaccuracies of certain components of the complete workpiece, which can change their position under certain conditions. In addition, the system should be easy to change over and include position visualisation to reduce potential handling errors.

Solution

NOYEN Expert C series is a machine designed for industrial washing of parts. This solution was developed for the automotive manufacturer. It enables washing of the most complicated parts according to the highest cleanliness classes. The functionality of the plant was fully adapted to the customer's requirements. The number, type and duration of the processes were adjusted. The washing and drying processes were optimised by adapting the positioning of the washing and drying nozzles to the geometry of the workpiece and by separating the washing and rinsing chambers. The NOYEN Expert C washing machine guarantees high efficiency due to short cycle times of a few seconds and simultaneous execution of all sub-processes. The machine is characterised by its compact size, so it does not take up much space in the production hall. The machine is operated by a robot that makes it fully automatic. 

The igus products were used to adjust the height of the workpiece holders. They were placed directly on the carousel that transports the parts between processes within the machine. Two SHT tables were installed in each of the six sections. The variant used solved the problems associated with the complexity and costliness of the classic solution. At the same time, the new method is lighter and adapted to the more difficult conditions of an industrial washing plant. Benefits resulting from the implemented solution include:

• The provision of the necessary regulatory parameters
• Ergonomics
• Significant reduction in manufacturing costs
• Simplification of the construction
• Weight reduction
• Acceleration of the assembly of the entire device
• Ensuring the repeatability of the components
• Achieving a high level of freedom from defects

In addition, the system has been improved in terms of reliability. Furthermore, the system has gained in terms of visual appearance. It looks simple and solid. The finally applied solution has proved to be so good that it can be found operating in unchanged form in many machines, for example, in Mexico, China, Germany or in some equipment in Poland.

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