Automotive brake cleaning

 

An ultrasonic cleaning system from Ultrawave has been installed into the manufacturing process at Continental Teves “Small Series” plant in Ebbw Vale, South Wales. The ultrasonic system was incorporated into the specification to improve the manufacturing process and has led to cost savings and a reduction in energy requirements. The manufacturing process of brake callipers requires parts to be machined and zinc plated prior to assembly. After acid pickling and 5 minutes in a de-rusting solution, smut can be left on the surface of parts causing poor coverage in the zinc plating stage. Ultrasonic technology was recognised as a potential solution to this cleaning problem.

Continental Teves already had a 7,500 litre tank which they were using for the cleaning process. In order to incorporate ultrasonic technology into the tank, Ultrawave submersible transducers were used. In total, Ultrawave supplied fourteen 1.5KW transducers which are located around the sides of the tank. Additionally, 7 transducers are deployed in the centre of the tank, producing ultrasonic activity in a 360 degree direction. Ultrawave supplied 21 PLC controlled generators to power the submersibles, housed in a purpose built cabinet. The variable factors of the system can be programmed including cycle time, heat and ultrasonic power, ensuring the process is tailored to exact requirements.

As well as reducing energy usage, the addition of the ultrasonic cleaning stage provides improved part quality results. The improved plating coverage has led to a reduction in the zinc wastage in the plating process while faster coverage in the low current density areas has sped up the overall process. The success experienced with the Ultrawave ultrasonic system has seen the use of ultrasonics included as an alternative to electro-cleaning in the Continental specification for zinc plating.