Our long-term customer operating in the automotive sector manufactures components for brake systems. One of the key parts they produce is an aluminum brake pump manifold. During machining, these components become contaminated with coolant and metallic chips, which requires precise cleaning of both the surface and the internal geometry before moving to the next production step.

What did the customer need?

The customer approached us with the need to design and manufacture a cleaning and degreasing system for aluminum brake pump housing components, enabling preparation of the parts for further assembly in compliance with automotive quality requirements. The process had to meet industrial cleanliness standards, including the requirement of zero particles above 600 μm. Effective removal of coolant, chips, and other loose contaminants was required from the outer surfaces as well as from numerous internal channels and bores. Additionally, after the process the components had to be completely dry, including all hard-to-reach internal areas. The biggest design challenge proved to be the method of handling the parts inside the process chambers, constrained by the technological assumptions of the project.

As a result, a basket was designed to function as tooling, which simultaneously enabled:

• rotation inside the process chambers to improve washing and drying efficiency,
• transportation using a lift system and a pusher, eliminating the need for a manipulator,
• preparing the structure for future automation of loading and unloading operations.

The project also had to take into account important infrastructural limitations at the customer’s facility, such as limited usable hall height and transport requirements related both to delivery of the machine and its movement inside the plant. This required a compact design and carefully planned arrangement of machine components.

Solution implemented for the customer

In response to the customer’s needs, we implemented the NOYEN ULTRA 1000 WWRRDVT system.

The cleaning process included:
1. Spray washing – initial removal of coolant and chips from external surfaces and internal channels using pressure and temperature optimized for aluminum.
2. Ultrasonic washing – generation of ultrasonic waves at an optimized frequency in a chemical bath to ensure thorough cleaning of hard-to-reach areas.
3. Ultrasonic and spray rinsing – effective removal of chemical residues and fine metallic particles, ensuring compliance with cleanliness standards.
4. Hot-air and vacuum drying – elimination of moisture from the surfaces and internal geometry of the manifolds; the use of air blow-off and vacuum prevents condensation and prepares parts for assembly.
5. Automated transport between chambers – full process automation with loading and unloading in a single zone, minimizing the risk of recontamination.

The cleaning cycle time amounted to approximately 200 parts per hour, maintaining high process efficiency with full quality control. Additionally, a chemical bath filtration and recirculation system was implemented, increasing bath life and reducing the frequency of chemical changes, ensuring stability of bath parameters.

Benefits for the customer

• Effective removal of coolant and aluminum chips from the surfaces and internal structures of the manifolds.
• Complete and repeatable drying of parts, eliminating the risk of corrosion.
• High throughput – approximately 200 parts per hour with a full wash, rinse, and drying cycle.
• Full process automation – reduced operator involvement and minimized error risk.
• Maintaining consistent cleanliness standards required for assembly.
• Optimized part flow in the plant thanks to integrated transport between chambers.

What did the customer gain from working with NOYEN?

Implementation of the NOYEN ULTRA 1000 WWRRDVT system enabled the customer to streamline the cleaning process of aluminum components, ensuring repeatability, automation, and full compliance with cleanliness standards. The solution improved production efficiency, reduced the risk of recontamination, and enhanced organization of part flow within the facility, positively impacting the quality of final products and the safety of the assembly process. An additional benefit is the high versatility of the cleaning machine, with appropriate tooling, it is also possible to clean other reference types.