Gear detail washing machine (Model: GWM-01)

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Gear detail washing machine (Model: GWM-01)

The gear detail washing machine GWM-01 is an industrial washing machine widely selected by many businesses for removing oil and grease from mechanical components, automotive parts, and motorcycle parts. With conventional methods of cleaning mechanical components such as gears, a large amount of labor is required to handle a high volume of products. This results in increased time and manpower requirements for the cleaning process before assembly, which can negatively affect the productivity of the entire production line. CNC VINA designs and manufactures automatic industrial gear washing systems according to each customer's specific requirements. By automating the cleaning process, the system helps significantly improve production efficiency and enables customers to increase productivity and profitability. Furthermore, the automatic washing system is equipped with oil separation and filtration units, helping maintain the quality of the washing solution and ensuring stable and reliable machine operation.

VIETNAM CNC & TECHNOLOGY APPLICATION JOINT STOCK COMPANY

Hotline: +84.916 63 9355 / +84.915 74 4664

Email: Sales01@cncvina.com.vn / Sales03@cncvina.com.vn

Product description

Article content

Technical specifications of gear detail washing machine

Main power supply	3 phase, AC 200 V, 50 - 60 Hz, 35 kW
Machine operating height	1500 mm from floor level
Control voltage	DC 24 V
Required air pressure	0.4 - 0.6 MPa
Machine construction material	SUS201
Power consumption	35 kW
Color	Optional

Structure and operating principle of automatic gear washing machine

The automatic gear detail washing machine is designed as a continuous production line, integrating multiple equipment units to perform the processes of product feeding, spray washing, washing solution filtration and circulation, air blow-off, and product discharge in a synchronized manner. Each unit performs a specific function and is interconnected through the control system and sensors, ensuring a stable cleaning process while minimizing manual operations. Depending on the size, shape, level of oil and grease contamination, and required cleanliness of each type of gear, CNC VINA can design and arrange the appropriate functional units.

Structure of the gear parts washing machine

The industrial gear parts washing machines have been supplied by CNC VINA to many major customers specializing in automotive and motorcycle parts manufacturing, such as MUSASHI, FCC, and others. Depending on the specific requirements of each customer and product, the industrial washing machine can be designed with different configurations. However, basically, the machine consists of the following main components and equipment:

– Transfer system and conveyor for feeding products into the washing chamber: This system receives and transports gears into the washing machine. It ensures that the products are positioned and oriented correctly while maintaining an appropriate spacing between parts for stable and effective spray washing.

– Washing system with spray nozzles: This is the main functional unit of the machine, using high-pressure water or cleaning solution to remove oil, grease, rust, dust, and other contaminants from the gear surface. The water or cleaning solution is pumped at an appropriate pressure through spray nozzles arranged around the product.

– Drying system: This system dries the washed parts after cleaning. After the washing process, water or cleaning solution may still remain on the gear surface. The drying system removes residual water, especially from gear teeth, holes, and other areas where water can easily accumulate. Typically, the system uses high-speed air or heated air to blow and dry the products. This helps minimize residual water, reduce the risk of oxidation and rust, and prepare the parts for subsequent machining or assembly processes.

– Circulation pump: Transfers the washing solution from the tank to the spray nozzle system for continuous washing.

– Sediment filter: Removes metal chips, dust, and other particles from the washing solution.

– Oil skimmer / oil removal unit: Separates oil and grease floating on the surface of the washing solution, helping maintain cleaning performance.

– Filtration system: Helps maintain the quality of the washing solution and prevents contaminants from returning to the spray system.

Thanks to this circulation and filtration mechanism, the washing solution can be reused, helping reduce solution consumption and maintain stable cleaning performance.

Operating principle

The gear washing machine operates based on an automatic product conveying system combined with recirculating solution washing and air blow-off for chip removal. The entire process is carried out continuously, from the moment the operator loads the gears after the deburring process until the cleaned products reach the output of the machine.

The operating process is as follows:

Operator loads Gear → Conveyor → Product Detection Sensor → Washing Valve/System Activated → Washing Chamber → Air Blow-off Chamber → Output → Operator Removes and Inspects Gear

Step 1: Loading the gear into the machine

After completing the deburring process, the operator places the gear onto the machine's infeed conveyor. The conveyor transports the product in the correct direction and moves it toward the washing area.

When the gear reaches the infeed detection position, the product detection sensor confirms the presence of the product on the conveyor. The sensor signal is sent to the control system to verify the operating condition and initiate the washing cycle.

Step 2: Activating the washing system

After the sensor confirms that the gear is in the correct position, the control system activates the washing solution supply valve and related equipment.

The washing solution is pumped from the clean solution tank through the circulation pump to the spray nozzles inside the washing chamber. The spray nozzles are arranged according to the shape and position of the gear so that the cleaning solution can directly reach the product surface.

Under the action of the pressurized cleaning solution, oil, grease, dust, metal chips, and other contaminants remaining on the gear after machining are removed.

For gears with multiple grooves, teeth, holes, or difficult-to-reach areas, multi-directional spray nozzle arrangements improve the cleaning performance and help ensure thorough cleaning of the entire product surface.

Step 3: Gear conveying through the washing chamber

The conveyor continues transporting the gear through the washing chamber. While the product passes through this chamber, the spray washing system operates continuously or according to a cycle programmed in the control system.

The residence time of the product inside the washing chamber is determined based on the actual requirements of each type of gear, including product dimensions, contamination level, amount of oil and grease, quantity of metal chips, and required cleanliness.

By controlling the conveying speed and washing process, each product undergoes a relatively consistent cleaning cycle.

Step 4: Recovery and filtration of the washing solution

After being sprayed onto the gear, the washing solution containing oil, grease, metal chips, and other contaminants flows down to the bottom of the machine and is collected in the dirty solution tank.

The contaminated solution then passes through the Oil skimmer. The Oil Skimmer separates oil and grease floating on the surface of the solution, reducing the amount of oil returned to the circulation system.

After the oil separation process, the solution is pumped into the filter tank. The filter retains contaminants, metal chips, and other particles of an appropriate size.

The filtered solution then flows into the clean solution tank, providing a reusable source of washing solution.

The circulation pump subsequently draws the solution from the clean tank and returns it to the washing chamber through the piping system and spray nozzles.

Step 5: Transfer to the air blow-off chamber

After completing the washing process, the conveyor transports the gear to the air blow-off chamber.

Here, the compressed-air system generates a high-velocity airflow to remove metal chips, water, and residual cleaning solution from the gear surface. The airflow is directed toward areas that require additional cleaning, particularly the gear teeth, holes, grooves, and areas where water or chips may accumulate.

This process helps improve the cleanliness of the gear and removes residual contaminants remaining after washing.

Step 6: Transfer the gear to the output position

After completing the washing and air blow-off processes, the gear continues to be transported by the conveyor to the machine output.

At the output position, the operator removes the gear from the machine for post-washing quality inspection. Depending on the production requirements, the inspection may focus on the presence of oil, grease, metal chips, residual contaminants, or the cleanliness of critical areas on the gear.

If the product meets the required quality standards, the gear is transferred to the next stage of the production line.

gear- CNCvina industrial wheel design

3D Model of the gear parts washing machine – All industrial washing machines, specialized machines, and custom-designed automatic machines manufactured by CNC VINA are visually and clearly illustrated for our customers, helping them better understand the machine structure, configuration, and operation.

Note: During operation, always follow the operating procedures and instructions developed by CNC VINA specifically for the customer's washing machine. Below are some common washing machine errors and troubleshooting methods for operators' reference.

Error overload washing pump / Error overload mist collector / Error overload oil skimmer / Error overload conveyor

Cause: The motor is overloaded.
Machine status: The system stops, the red indicator light turns on, and the HMI displays the error message “Error Overload Washing Pump...”.
Action: Check the electrical connections for short circuits or other connection problems. Tighten the connection terminals if necessary. Reset the system and restart the machine.

If the error cannot be resolved after performing the above troubleshooting steps:

Check the equipment wiring to ensure that there are no loose, broken, or disconnected wires or terminals.
If the wiring is normal, check whether the corresponding equipment is still operating properly.
If the equipment is not functioning properly, turn off the power to the entire system, then restore the power and initialize the system from the beginning.

Outstanding features of the gear detail washing machine:

The washing machine is specifically designed to wash gears with 3 washing cycles and a drying cycle using a solution of water and cleaning oil.
The gear washing machine has two operating modes: automatic and manual. Display buttons, switch systems, and indicator lights help the operator easily recognize machine operations quickly and promptly.
The cylinder and mounting system are calculated and designed to suit the machine's features.
The system of filter pumps, filter bags, and oil skimmers help circulate the washing solution to maximize washing solution savings.
Mist collector ensures the health of workers and the surrounding environment.

The gear detail washing machine is an effective automation solution for manufacturers of automotive parts, motorcycle components, and mechanical parts requiring high cleanliness standards. With continuous conveying, washing, filtration, and air blow-off processes, the machine significantly reduces manual operations and product cleaning time. The high-pressure spray system combined with air blow-off processes effectively removes oil, grease, metal chips, dust, and other contaminants remaining on the gears after machining. In addition, the Oil Skimmer, filtration system, and circulation pump help maintain the quality of the washing solution, reduce solution consumption, and contribute to stable machine operation. The machine is designed according to each product and the actual production requirements, including gear dimensions, production capacity, and required cleanliness level. The application of an automatic washing machine not only improves productivity but also helps reduce labor costs and ensure more consistent product quality after cleaning. With extensive experience in designing and manufacturing custom automatic machinery, CNC VINA can provide consultation and develop gear parts washing solutions tailored to each company's specific production process.

VIETNAM CNC & TECHNOLOGY APPLICATION JOINT STOCK COMPANY

Factory: Song Cung Industrial Site, Dong Thap Commune, Dan Phuong District, City. Hanoi Vietnam

Phone: +84.916 63 9355 / +84.915 74 4664

Website: www.cncvina.com.vn ; www.cncvina.net

Email: Sales01@cncvina.com.vn | Sales04@cncvina.com.vn