1. Main Cleaning Difficulties of Differential Housings

The workpieces are made of cast aluminum or cast iron, featuring complex structures with deep inner cavities, dense oil passages, threaded holes and dead corners. Typical contaminants include cutting oil, cutting fluid, iron filings, casting sand, anti-rust oil and polishing wax.

Core Technical Requirements

1. Meet VDA19/ISO16232 cleanliness standards: particulate residue ≤ 0.5 μm, free of oil film and dirt residues.

2. No water stains, rust or oxidation, especially for aluminum alloy components.

3. Ensure oil passages and threaded holes are unclogged and free of iron filings.

4. Support full-automatic operation to match assembly line tact time and product traceability.

2. Recommended Processes (Hydrocarbon Vacuum Cleaning Preferred)

Solution A: Fully Automatic Multi-station Hydrocarbon Vacuum Cleaning Machine

Application: Mass production with annual output over 100,000 pieces, high cleanliness requirements, suitable for both cast aluminum and cast iron housings.

All procedures are completed in a fully sealed vacuum environment:

1. Automatic loading (manipulator / material tray)

2. Vacuum spray rough cleaning (0.5–0.8 MPa) to flush inner cavities and oil passages

3. Vacuum ultrasonic fine cleaning (28/40 kHz) to remove dirt from deep holes and threaded holes through cavitation

4. Targeted vacuum spraying for oil passages, flange surfaces and threaded holes

5. Vacuum vapor rinsing for thorough decontamination

6. Vacuum distillation drying (temperature ≤ 50 °C). The oxygen-free and moisture-free environment ensures complete drying.

7. Solvent vacuum distillation and recycling (recovery rate ≥ 95%)

8. Automatic unloading and connection to inspection stations

Cleaning Medium: Special Sinobakr hydrocarbon solvent (flash point ≥ 62 °C, low VOC)Equipment: BK series multi-station hydrocarbon vacuum cleaning machine

Solution B: Single-chamber Vacuum Hydrocarbon Cleaning Machine

Application: Small and medium-batch production with high cleanliness demands.

Process flow: Loading → Vacuum ultrasonic cleaning → Vacuum rinsing → Vacuum drying → Unloading

Advantages: Low investment cost, high flexibility and fast model changeover, ideal for multi-product production.

Solution C: Combined High-pressure Spray & Ultrasonic Cleaning

Application: Cost-oriented projects, mainly for cast iron differential housings.

Process flow: Loading → High-pressure spray cleaning (0.8–1.2 MPa) → Ultrasonic cleaning → Rinsing → Hot air drying

Disadvantages: Likely to produce water stains and rust; maximum achievable cleanliness ≤ 5 μm; additional wastewater treatment is required.

3. Standard Equipment Configuration (Sinobakr)

3.1 Main Equipment: BK-5144RYH 5-station Hydrocarbon Vacuum Cleaning Machine

• Chamber: 304 stainless steel, fully sealed and explosion-proof

• Ultrasonic system: Dual frequency of 28 kHz / 40 kHz, power: 3–6 kW

• Spray system: Working pressure 0.5–0.8 MPa, dedicated nozzles for oil passages and threaded holes

• Vacuum degree: ≤ -0.09 MPa

• Drying: Vacuum distillation drying, no water marks or oxidation

• Solvent recovery: Built-in distillation system, solvent recovery rate ≥ 95%

3.2 Tooling & Automation Accessories

• Custom fixtures: Designed for differential housings, supporting 360° rotation

• Loading & unloading system: Manipulator or roller conveyor for production line integration

• Filtration system: Three-stage precision filtration (10 μm → 5 μm → 1 μm)

• Optional devices: Cleanliness detector, particle counter

4. Key Performance Parameters

• Cleanliness: Compliant with VDA19/ISO16232, particulate residue ≤ 0.5 μm

• Drying effect: No water stains, rust or oxidation; aluminum alloy parts keep intact without discoloration within 72 hours

• Cycle time: 6–12 minutes per workpiece; shortened to 3–5 minutes via multi-station parallel operation

• Solvent consumption: ≤ 5 g per workpiece (recovery rate above 95%)

• Energy saving & environmental protection: Energy consumption over 30% lower than water-based cleaning; zero wastewater discharge