Sinobakr Modified Alcohol Cleaning Solution for Precision Gears

1. Application Scenarios & Pain Points Solved

Applicable Gear Types

New energy reduction gears, humanoid robot precision gears, aerospace/automotive transmission gears, miniature servo gears, powder metallurgy gears, heat-treated quenched gears, stainless steel/alloy steel/aluminum precision gears.

Core Cleaning Pain Points Addressed by Modified Alcohol Solution

1. Residual cutting oil, quenching oil, grinding dust, polishing wax and metal micro-debris trapped in tooth roots, tooth gaps and blind holes, leading to abnormal noise, wear and jamming after assembly.

2. Aqueous cleaning tends to leave water stains, cause surface oxidation and short-term rusting, failing to meet the 6-month long-term rust prevention requirement.

3. Conventional hydrocarbon solvents feature low flash points and high VOC emissions, posing obstacles to environmental assessment and production permits.

4. Manual/open cleaning results in high solvent loss and unstable cleanliness, unable to consistently reach NAS 8~NAS 10 cleanliness levels.

5. High-end gears require zero ionic residues, no water marks and thorough drying to match high-precision assembly standards.

Core Advantages of Sinobakr Modified Alcohol Solution

1. Eco-friendly & SafeHigh flash-point modified alcohol applied in fully sealed vacuum chambers (<100 mbar) delivers near-zero VOC emissions, complying with national hazardous waste and industrial park environmental regulations. Low-toxicity and biodegradable with no ozone depletion potential (ODP).

2. Deep Cleaning PerformanceVacuum negative pressure eliminates air bubbles in tooth gaps, enabling solvent penetration into micro-gaps as narrow as 0.05 μm. Combined with high-frequency ultrasonic waves and 360° rotating spray, it completely removes oil contaminants and metal dust in one cycle. Post-cleaning particle impurities ≤300 μm, meeting aerospace and robot gear cleanliness standards.

3. Material CompatibilityNeutral solvent with no corrosion risks to alloy steel, carburized gears, aluminum parts, nitrided or electroplated surfaces; no tooth surface discoloration or hydrogen embrittlement.

4. Low-Cost RecirculationBuilt-in vacuum distillation fractionation system automatically separates cutting oil and water, achieving over 95% solvent recycling rate. Single-run consumable cost far lower than trichloroethylene and multi-stage rinsing aqueous processes.

5. Residue-Free Drying with Rust ProtectionLow-temperature vacuum drying completes solvent removal within 30 seconds without water marks or solvent spots. Integrated short-term anti-rust formula allows direct assembly or 6-month sealed storage after cleaning.

6. Fully Automatic Intelligent OperationSiemens PLC touchscreen control, automatic loading/unloading, basket flipping, continuous oil draining and filter replacement reminder. Single cleaning cycle ranges from 8 to 16 minutes, compatible with mass production assembly lines.

2. Sinobakr Special Modified Alcohol Cleaners for Gears

Model BAK-MA100 Standard Grade (Post-machining Finished Gears)

• Application: Post-hobbing, turning and grinding gears for removing cutting fluid, drawing oil and fine grinding powder

• Specifications: Flash point ≥65°C, neutral and non-corrosive, purity 99.5%, free of chloride ions and heavy metal ions

• Matching additive: 0.1%~0.3% gear-specific anti-rust dispersant to prevent re-adhesion of metal micro-powder on tooth surfaces

Model BAK-MA200 High-Temperature Grade (Heat-Treated Quenched Gears)

• Application: Quenched and tempered gears with residual quenching oil, oxide scale and high-temperature carbon deposits

• Specifications: Strong solvency to strip coked oil sludge; no residues after vacuum distillation, keeping tooth surfaces free of dull discoloration post-cleaning

Model BAK-MA300 Ultra-Pure Electronic Grade (Aerospace & Humanoid Robot Micro Gears)

• Purity ≥99.99%, metallic ions (Na/K/Fe) ≤0.001 ppb, particle impurities ≥0.1 μm ≤1 particle/mL, meeting ultra-high NAS 8 cleanliness requirements

3. Sinobakr Modified Alcohol Cleaning Equipment Selection by Production Capacity

1. Single-Chamber Fully Automatic Modified Alcohol Cleaner (Small Batch & Sample Testing)

• Structure: Single vacuum cleaning chamber integrated with vacuum spray, 60~80 kHz high-frequency ultrasonic, steam rinsing and vacuum drying

• Output: 1~5 baskets per hour, suitable for R&D samples and small-batch precision gear production

• Benefits: Small footprint, low investment, one-touch automatic programs with adjustable gear cleaning parameters

2. Dual-Chamber / 5-Station Fully Sealed Modified Alcohol Cleaning Line (Medium & Large Mass Automation)

• Integrated processes: Loading → Vacuum Rough Spray Cleaning → Ultrasonic Fine Cleaning → Solvent Steam Rinsing → Vacuum Dehydration & Drying → Unloading

• Optional configurations: Robotic automatic loading/unloading, 360° basket flipping, fixed-point high-pressure spray for enhanced tooth root cleaning

• Applicable to mass production lines for new energy drive and automotive transmission gears

Standard General Hardware Configuration

• Integrated 304 stainless steel inner tank with seamless welds to avoid dirt trapping

• PID constant temperature control (±0.5°C), adjustable cleaning temperature 40~50°C

• Vacuum distillation recovery system + multi-stage precision filtration (0.1 μm precision filter elements)

• Heat recovery energy-saving system utilizing waste steam heat to preheat cleaning tanks, cutting energy consumption by 30%

• Explosion-proof electrical control with multi-layer safety interlocks for overload, over-temperature and vacuum leakage protection

4. Standard Precision Gear Cleaning Process (Mature Sinobakr Process)

Total cycle time: 10~14 minutes per basket, compatible with most precision gears

1. Loading & Basket PlacementLayer gears to avoid contact and shielding of tooth surfaces; hollow fixture baskets with flipping mechanisms recommended for mass batches.

2. Vacuum Pre-Soaking (2 min, 50~80 mbar vacuum)Evacuate air from tooth gaps under vacuum for full penetration of modified alcohol into tooth roots, splines and inner bores to dissolve heavy oil contaminants.

3. Vacuum Rough Spray Cleaning (2 min)360° high-pressure solvent spray flushes large metal debris and cured oil sludge, with automatic oil separation to drain heavy pollutants.

4. High-Frequency Ultrasonic Fine Cleaning (3~4 min, 60~80 kHz, 60~80 W/L)Low-power high-frequency ultrasonic waves prevent scratching of tooth surfaces with Ra ≤0.2 μm. Cavitation strips micron-scale grinding powder and polishing paste; repeated vacuum-purge cycles boost penetration efficiency.

5. Solvent Steam Rinsing (2 min)High-purity modified alcohol steam shower removes trace contaminants carried over from cleaning tanks to prevent secondary surface pollution.

6. Graded Vacuum Drying (2~3 min, low temperature 30~45°C)Negative pressure rapidly extracts residual solvent for spotless, residue-free bright tooth surfaces.

7. Unloading, Inspection & StorageCleanliness inspection via gravimetric method/particle counter; finished gears ready for direct assembly or sealed anti-rust packaging.

Process Parameter Adjustment for Different Scenarios

1. Heat-treated quenched gears: Extend ultrasonic cleaning to 5 min, raise cleaning temperature to 48~50°C, adopt MA200 high-temperature modified alcohol

2. Micro humanoid robot gears: Use MA300 ultra-pure solvent, double steam rinsing, extend drying to 3.5 min to reach NAS 8 cleanliness

3. Powder metallurgy gears: Reduce ultrasonic power to 50 W/L, prolong pre-soaking time to avoid powder entrapment in pores

5. Post-Cleaning Cleanliness & Rust Prevention Guarantee

Cleanliness Standards

Solid residual particles <300 μm, total impurity weight per single gear <0.5 mg, zero oil film and ionic residues, complying with assembly acceptance standards for new energy motors and robots.

Rust Prevention Performance

Built-in neutral anti-rust components in modified alcohol; cleaned gears remain rust-free for 6 months under indoor bare storage. For long-term warehousing, match with Sinobakr ultra-thin displacement anti-rust oil with no impact on meshing precision.

Supporting Testing Services

Sinobakr in-house laboratory provides gravimetric cleanliness testing, particle analysis, ionic contamination testing and tooth surface roughness comparison with official test reports.