Volume 5 www.sonicairsystems.com Issue 5

Sonic Air Running on all Cylinders Customer: Major Automaker in West Virginia, USA Sonic Sales Partner: Applied Fluids LLC - OH Application: A major auto maker had a plan to incorporate multiple blow-off stations to remove rinse water from their 4-cylinder engine block assembly. The surface understandably is complex with multiple blind holes, through holes, grooves, etc.. And if those areas retain any water, the result could be complete failure. This particular plant was given an award in September 2004 for most efficient engine assembly in North America. It was the second straight year that this plant topped the rankings in the assembly of both four-cylinder and six-cylinder engines. So when it came time to installing new equipment, there was a concern to meet their strict standards. The engine plant contacted Sonic which they knew as a manufacturer of blow-off systems. Sonic’s local Rep, Applied Fluids, visited the plant and gathered all of the application and installation details. The Sonic Sales Engineers chose the “Rotary” (patent pending) air knife would be the perfect fit to accomplish their goal. This particular plant had just hit a major milestone by producing their one millionth engine and transmission. Their total plant investment will be $950 million with a yearly production capacity of 340,000 4-cylinder engines. Application: The process included rinsing of the 400mm L x 360mm W x 310mm H engine block rinsed with 80°F combination of wash solution and rinse water. The next process for the assembly was a trip to a press machine to place plugs in oil passages, where any remaining water would turn detrimental. The blocks are processed on a chain conveyor at a production rate of (2) parts per minute. The plant also needed a fast solution since their current dryer was ineffective and was not acceptable any longer. Sonic “Engineered” Solution: Sonic proposed the use of Rotary Air Knives on top and standard knives placed diagonally from top to bottom for side blow-off. Due to the complexities of the blocks along with the slow production rates, proved to be a perfect match for the Rotary. The Rotary knife allows for a rotational speed of up to 200RPM. By rotating the knife, and subsequently the air velocity, it allows multiple passes of that high velocity air to impact the part surface multiple times, but with only (1) knife. A job with these types of complexities would require other solutions to include up to (6) knives on the top to accomplish the same dryness. The rotary technology drastically reduces the required horsepower and proves to be the most cost effective solution, taking up the least amount of line space.

Published by: Sonic Air Systems, Inc. 1050 Beacon St, Brea, CA 92821 (714)255-0124 © 2005 Printed in US. Email asksonic@sonicairsystems.com