Water jackets cleaning

One of the more difficult areas to clean in the cylinder heads and cylinder blocks of the automobile engines is the water jackets,Why?

1) The internal volumes of the water jackets are complex and very often with narrow passages. By one side the cylinder head designers wants to have a minimum water jacket volume in order that the engine can rise in temperature rapidly to have the optimum engine performance. By other side is important to refrigerate all the areas of the cylinder head , mainly around the combustion chambers , but the number of valves per cylinder create narrow passages inside the water jackets.

2) On the machining of the aluminium alloys the cutting speed are more and more elevate and create longs chips . The cycles times on the machines are more and more shorts and there is not too much time to break the chips.On the transfer lines it was easier to do than in the present CNC flexible lines.

3)As consequence of the cutting speeds and short cycle times the chips are very often pushed inside the water jackets by the final milling tools.

4) The consequence of long spring chips inside small pockets and narrow passages  is chips trapped inside the water jackets.

The cylinder head is more sensitive to this problem but some cylinder block too. Here joint you can see what you can find inside a cylinder head water jacket:

       There is a clear test : If we cut a supposed clean cylinder head in slices it will allows us to see if there are some chips trapped inside the water jacket. I’ll say that the majority of clean cylinder heads have chips inside.

Is dangerous for the engine run? Well, first you have to assembly your engine (cylinder head , cylinder block , camshafts, crankshaft..). During the automatic assemply this remaining chips can fall down of the parts and goes to the assembly machine or between the parts to be assembled blocking the operation and stopping the machine and the line.

Second if you assembly your engine with no problem but the chip remain inside , is possible than during the engine run with the vibrations and , temperature changes , the chips goes out of the water chamber and arrives to the water pump causing the failure of the water pump , heating the engine and stopping the car engine.

Another added problem is the remaining sand balls remaining inside the water jackets coming from the cast process:

 

 

 

Since many years this water jacket problem has been the major nightmare for the equipment suppliers and for the automotive industry .

The process to remove the remaining sand inside the water jackets  is called “desandind” and will be considered in a further post . today we will concentrate only in the chips removal :

Some suppliers were using a contact jet at 20/30 bars to flush inside the water jackets( ICOM, Hafroy). Or” injection flood” ( Dürr) injecting 10/15 bars jet against the waster jacket on immersion of the part . Or the “Aqua cannon”(Valiant) with a medium pressure short discharge inside the part pulsing the water inside. 

Or the High pressure ( 200 bars) target injection trough the part openings (Agullo).

Or a mixture of systems like Sugino .

In any case the problem is a difficult problem and needs test with real parts to achieve an acceptable process. Of course the automobile client is also an important part. If the cleanliness test to control the cleanliness of the cylinder head is a manual flushing of a solvent trough the part( and water jacket ) is probably than the flushing (normally at 1 to 3 bars) will not be able to remove the blocked chips inside the water jackets and the test can give a result of accepted clean part when it has trapped chips inside the water jackets.

Some cleanliness tests in the automobile have added operations to the cleanliness test procedure to verify these water jackets. One is the manual hammer percussion by the operator of the cylinder head in a certain position in order to detach the chips balls inside . I remember than years ago in an european engine manufacturer the company Hafroy supplied one transfer machine that had a pneumatic hammer in one of the Ferris wheel wash stations to reproduce the operator cleanliness test operation and try to remove this balls. I remember that the line operators call the machine the “Bell” ( a “dong” each 30 secs was not appreciated by the operators around the line).

Another system is the manual checking of the water jackets with a small  endoscope . This system is of course the more efficient but some times you can not reach all the internal areas. Only cutting the cylinder head you can really check it.

To reduce the chips and traps inside the water jackets is necessary a close work between the cylinder head designers ,cylinder head  machining engineers and the “cleaning” engineers to avoid narrow passages inside the water jackets design , to avoid big and spring chips during the machining, to have high coolant volume during the machining , or cover plates during machining . If you diminish the size of the chips , if you avoid the spring chips , if you avoid narrow passages and traps inside the water jacket , if you have more than one opening of the cylinder head water chambers you will have more opportunities to remove the inside trapped chips.

Maybe one of the Automobile manufacturers that pay more attention to the water jackets has been Fiat . In their wash process specification the request several water jacket wash operations in each of the washers of the cylinder head line. More water jacket wash operation you have with the part in different positions and injecting the water by different areas to create different flows inside the water jackets allows them to have more opportunities to remove the chips. Of course this redundant system is expensive and the present tendency in the Automotive industry is to reduce the number of washers in the lines.

In any case the miracles are impossible and if you really check inside your cylinder head water jackets(or cylinder block water jackets) you have to pay attention to the whole manufacturing process including the more effective wash processes to remove the trapped chips and to have a really clean part.

 

A good system is to collect and classify all the chips shape produced in the machining line , operation by operation .  

And then looking to the chip type remaining inside the W.J. you can identify in which machining operation the chip is produced and penetrates in the W.J. Working with the machining process engineers it comes very often the possibility to reduce the size of the chip or to eliminate the quantity remaining in the parts

 

The automobile cleanliness tests procedures are also an interesting point to be examined in a further post. They are the reason why some time one washing machines that is a good machine for an automotive manufacturer but fails in another manufacturer.

Crisis, bloody 30%

Today I want to talk of this new alteration of the market : the Economy and Financial Crisis.

The 10Th January  I read on news papers: “Ssangyon Motor(Korean cars company) collapsed , they stops their payments due to 30% drop on sales and will reduce work forces and costs for 30%”.

On the following days I see : 2008 car sales in USA drop 30 to 40% ; GM -48,8 % , Ford -40,6% , Chrysler -55% , Toyota -34,45% , Honda -30,7%,Nissan -29,7%,Daimler AG -35,5% , Porsche -36%…

The outlook for 2009 is also pesimistic with -30% sales.

In summary I hope that this bloody number “30%” is becoming  more and more familiar in our day to day life.

We have lost in 2008 30% of our homes value , 30% or our wealth , we are 30% poorer , we will reduce our expences by 30% . We will reduce our holidays by 30% …

Your clients have lost 30% of their sales , they are planing to reduce 30% their work forces and expenses , they will drop at least 30% their buys to suppliers.

They will ask for 30% reduction in the machines price to cover a 30% reduction in investments.

The suppliers will reduce by 30% their work forces to reduce costs. The Banks are reducing 30% the credits to the companies , and asking for 30% more coverage for new credits.

This pressure will have the consequence that 30% of the suppliers of the automotive industry ( and also wash-deburr suppliers) will probably disappear in the next months.

All that will come also with a certain “nationalism” on investments to keep working the country,despite the promises to respect  the free market of the politics .

When an American company will make a new invest , the American suppliers will be in advantage against an European or Japanese supplier. When a German company will make a new investment , the German suppliers will be in advantage against the French,Italian, English or other suppliers.

When an English company will make a new investment the English suppliers will be in advantage against a German ,French,Italian …supplier (despite the second advantage of the currency with a low pound against the euro. The Sterling lost 30% against the euro in 18 months)

I remember that in the 1970’s, 1980’s and 1990’s there was also economic crisis producing a reduction in the number of wash-deburr suppliers , but they were “local crisis” focused on one or two countries . Now in this global world , where the suppliers have been pushed  to be also global , the crisis is global and the consequences will be harder.

The clients and the banks will give tough days to the suppliers companies .  Which companies will disappear? Maybe taking in consideration the way that the German Banks have been always involved in their industry and their past experiences , the German Banks will better support the local industry than in France or Italy the other Banks will do .

The reduction of work forces in the wash-deburr manufacturers directly influenced by this economic and financial crisis , and the reduction of the number of suppliers , will fire a lot of knowledge  and experience out of these companies.

The wash-deburr manufacturers work is not a mathematical or ruled work .Is based on the experience of their engineers and fitters . Its a pity to lose all that and the companies making the personnel reductions would have to protect this knowledge , and think that after any storm it comes the calm , and in two or three years if they are still  alive they will need them.

Is also important to consider that in any case the small companies can have also their opportunities against the big companies in this crisis. The flexibility , innovation , quick reaction , relations , financial wellness , and cold blood will continue to be an asset today to defeat this bloody “30%” figure.

Good luck¡

Crisis maldito 30%

Hoy quiero hablar de este nuevo evento que ha aparecido distorsionando el mercado: la crisis Financiera y Económica.

El 10 de enero leí en las noticias: Ssangyon Motor (empresa Coreana del automóvil) hace suspensión de pagos, por la caída del 30% de sus ventas y reducirá un 30% los empleos y los gastos.

Al cabo de unos días veo: 2008 las ventas del automóvil en estados unidos caen un 30 al 40%; GM -48,8 %, Ford -40,6%, Chrysler -55%, Toyota -34,45%, Honda -30,7%, Nissan -29,7%, Daimler AG -35,5%, Porsche -36%…:

Las previsiones para 2009 también son pesimistas con caídas del 30% de las ventas.

En resumen este maldito 30% se está volviendo cada día más familiar en nuestra vida cotidiana.

Hemos perdido en 2008 el 30% del valor de nuestras viviendas, 30% de nuestro patrimonio, somos un 30% más pobres. Reduciremos nuestros gastos un 30%, reduciremos nuestras vacaciones un 30%…

Los clientes han perdido 30% de sus ventas, y están planificando reducir 30% de empleos y gastos y reducirán también 30% las compras hacia sus proveedores.

Los clientes pedirán 30% de reducción en los precios de las máquinas a sus proveedores para reducir así un 30% sus inversiones.

Los proveedores reducirán un 30% sus empleados y gastos.

Los bancos están reduciendo un 30% los créditos a las empresas y piden un 30% más de margen de cobertura  en las pólizas de crédito.

Esta presión tendrá como consecuencia que el 30% de los proveedores de la industria mecánica (y en consecuencia también los proveedores de equipos de lavado y desbarbado) probablemente desaparecerán en los próximos meses.

Todo esto vendrá agravado por un cierto “proteccionismo” en las inversiones para dar trabajo al propio país a pesar de las promesas de los políticos de respetar el libre Mercado.

Cuando una empresa americana haga una nueva inversión, los suministradores americanos estarán en ventaja respecto a uno europeo o japonés…

Cuando una empresa alemana haga una nueva inversión, los suministradores alemanes estarán en ventaja respecto a uno francés, italiano, ingles u otros.

Cuando una empresa inglesa haga una nueva inversión los suministradores ingleses estarán en ventaja respecto a los suministradores alemanes, franceses,  italianos  u otros (aparte de la protección adicional de que disfrutan con la situación de la divisa inglesa. La libra inglesa ha perdido un 30% de su valor respecto al euro en los últimos 18 meses)

Recuerdo que en los ‘70, ’80 y ’90 hubo también crisis económicas que fueron la causa del cierre de multitud de empresas y suministradores de equipos de lavado y desbarbado para la industria mecánica, pero fueron unas crisis locales concentradas en uno o dos países al mismo tiempo. Ahora en este Mundo global en el cual los proveedores han sido empujados a ser también globales, la crisis es global y las consecuencias serán mucho más graves.

Los clientes y los bancos serán una pesadilla para los proveedores.

Qué empresas desaparecerán? Quizás teniendo en cuenta cómo los bancos alemanes siempre han estado involucrados en la industria local y de acuerdo con lo sucedido en años pasados, los bancos alemanes se aliarán y soportarán la industria alemana mejor que los bancos franceses, italianos o ingleses harán con su propia industria local.

La reducción de empleos en los proveedores de equipos de lavado y desbarbado directamente afectados por esta crisis económica y financiera y la reducción en el número de proveedores será la causa de la pérdida de experiencia y conocimiento y saber hacer, fuera de estas empresas.

El trabajo de estas empresas de equipos de lavado y desbarbado no es un trabajo matemático, repetitivo o normalizado. Este trabajo esta basado en la experiencia de sus ingenieros y montadores. Es una pena perder todo este conocimiento y experiencia y las empresas que van a reducir personal deberían proteger todo este conocimiento y pensar que después de la tempestad viene la calma y en dos o tres años(si todavía están vivas) tendrán necesidad de ellos.

Es también importante considerar que en cualquier caso en esta crisis,  las pequeñas empresas pueden tener también sus oportunidades frente a las grandes empresas competidoras. La flexibilidad, innovación, rapidez de movimientos, relaciones, salud financiera y sangre fría continuaran siendo unos importantes activos para derrotar este maldito 30% que nos está azotando.

 

The USA mistake

 

Today I would want to remember the big mistake of some European and Japanese washers manufacturers in the Automotive American industry  middle 1990’s .

Sometime the successful manufacturers of one continent try to introduce their products in other continent without considering the difficulties due to the philosophy of the washer concept in each continent.

Sometime the customers of one continent wants to punish or improve their present manufacturer suppliers buying machines to a supplier from another continent without considering the difficulties due to the philosophy of the washer concept in each continent.

This happened in the 1990’s with the Japanese SUGINO . Ford Motor co placed orders for gear boxes high pressure washers to them(I hope it was in Livonia factory). The machines were of Japanese concept , giving good cleanliness quality but not appropriated to the maintenance requests from the American users ( accessibility , inside room, safety devices, documentation..). In conseque the application was a fracas and SUGINO didn’t had continuity in Ford.

In another case Ford Motor ordered a high pressure transfer wash/deburr for aluminium cylinder heads with also brush deburring.The supplier was the German company Beyss. The machine had a very complete process with brush deburring, cavitation wash, high pressure wash , ferris wheel.

When the machine starts to work in the factory( Romeo?) all the American normal washers suppliers were invited to see and appreciate the top of the technology in washing machines.  Not more than two years later the machine was a nightmare for the client due to his high complexity and the quantity of chips remaining inside the machine .The maintenance was difficult for the customers people,they were not trained for the job( complexity,controls, safety standards..).In consequence the application was a fracas and Beyss didn’t had continuity in Ford. Beyss lost a lot of money .

The American Automobile market had some particularities not present in Japan or in Europe:

 1) The car engines were much bigger . V engines of 3 to 6 litters volume. These sizes in Europe would be considered truck engines , not car engines.

2) The throughput in America was 200 to 300 parts /hour . In Japan or Europe the throughput was between 100 and 125 p/h

3) The tendency in Europe was to install sophisticate automatic filters for the wash liquid filtration with small tanks to have a minimal quantity of  liquid  in  the machine, when in America the tendency was opposite : big tanks simple filters and safety manual bags filters.

4) The amount of chips arriving to the machine with the parts was much bigger ( three to four times) than in Europe.

5) The detergents used in America were restricted to the environmental request of the State and in was not easy to use new ones used in Europe.In America the customers were working at ambient temperature ( witout machine heating)

6) The maintenance request in America were different. The “sizes” of an American foreman were much bigger than the Japanese foreman or European foreman. The machine access had to be bigger and easier in America .

7) The preventive maintenance philosophy in America was different: better to change a mechanical part after a certain number of working hours , than to check frequently how is it ,and evaluate if it has to be changed. It was more a “big maintenance” when needed than an small “periodic maintenance” to prevent a “big maintenance”.

8)The mechanical robustness of the machines in America was bigger than in Europe or Japan ans less sophisticate . For this reason the high production machines were hydraulic driven instead of electromechanical. The American hydraulics  standards were very constrained for the Europeans or Japanese  with inexperience and a high cost for them.

Al theses particularities were not well evaluated by Sugino, Beys… and caused their failure but it was also the pressure of the customers that forced them to deliver without enough analyses of the Market needs.

This was the situation when the company AGULLO arrives to the American market. People in Ford USA saw the Agullo Ferris wheel washing transfer machines in Ford Europe and wants to try it in America.

Then the american premium washer suppliers were Ingersoll (Centri-Spray), and Valiant on the Ferris wheel machines and Rocktool,and Liquiburr( in bankrupt) on high pressure.

Knowing the American particularities , AGULLO arrived to this market with the Ferris wheel machines( in line transfer with two vertical rotary tables across) for the cylinder blocks and cylinder heads.

The machines were in stainless steel body, with big tanks , robust mechanics, total accessibility (full side wall as motorized vertical guillotine door) for the maintenance, high pressure wash, and machine tool mechanics quality. In Chrysler with individual automatic filters , in Ford with Central filtration systems.

These machines astonish the customers and competitors. Some American suppliers commented the machines to be like the  ”Cadillac “of the Washers.

 

 

The majority of the machines are still working and have been retooled for new engines. This is an example to show that the washing machines are specific machines linked to a market and demands of a market and that before to go to other markets ,other customers, other requests,other mentalities, all the details have to be analysed in dip  .

The training of the customer is also important because if the machines are of a new technology for him , the operation and the maintenance is new and without a hard support from the supplier it could defeat.

Years later another example of that happen when one Automotive customer wants to buy exactly the same machines that he saw in Germany working in cylinder heads and cylinder blocks featuring new technologies for the Americans : hot cavitation wash, oil evaporators and vacuum dry. The machines were running successfully in Europe but not in America. Two years after the installation , the customer was enable to run the machines . ( tanks too small , foaming , parts too hot for the leak test , difficult maintenance , not enough training for the maintenance people in the factory, documentation not adequate…). The  consequence : the supplier was banned for several years in the customer Factories.

The washing machines are special machines receiving the hardest working conditions in the automotive factory : aggressive detergents , agresive machining oils and coolants , chips , helical chips , flat chips , burrs , liquid temperature , full humid ambient , temperatures changes , air condensations , noise , PLC or CNC  machine tools standards , rust atmosphere… and nobody likes to maintain it ( it is a dirty job…).The machine needs a good maintenance people understanding of chemicals , electronics, mechanics , lubrication , and also “process”(wash-blow off).

To be successfully on the utilisation of a washing machine from one Continent in the other is necesary the full implication of the washer manufacturer with the customer factory engineers , and factory maintenance people (not only the customer’s purchase or staff )before the construction of the machine. Is the only way to be successfully and that the machines and the washer manufacturer can last time in the customer preferences.

Maybe the future would be that the washer manufacturer has also the responsability for the maintenance and warranty the machine performances? .I know that the are some customers looking for that.

The machine engineering of the AGULLO washers in America inspired to several american manufacturers who updated their design and technologies and incorporate to their machines some AGULLO particularities like the  robustness, mechanics or the full size guillotine door( See Valiant , HMM pictures)