Systems and methods for the removal of ferrous debris from degreaser baths

1. A degreaser tank for removing debris from vehicle assemblies, the degreaser tank comprising:

a perimeter having at least one side wall, and a bottom surface cooperating to define a holding tank with an interior configured to store an alkaline degreaser to remove debris from at least one vehicle assembly; and

a debris removal flushing station located along the at least one side wall, the debris removal flushing station comprising:

one or more electromagnets adjacent to an exterior of the holding tank and configured to attract metal debris on the at least one side wall;

a drain port located at the at least one side wall, a distance below the one or more electromagnets; and

a supply line located a distance above the one or more electromagnets and configured to selectively provide a stream of alkaline degreaser toward debris, and directed to the drain port.

2. The degreaser tank according to claim 1 , wherein the perimeter defines a plurality of side walls and the degreaser tank comprises a plurality of spaced-apart debris removal flushing stations at various side wall locations throughout the holding tank.

3. The degreaser tank according to claim 2 , further comprising a controller configured to control a frequency of a flushing operation of the debris removal flushing stations.

4. The degreaser tank according to claim 3 , wherein the controller is configured to engage the flushing operation of each debris removal flushing station using a predetermined cycle based on at least one of:

a production volume of vehicle assemblies being cleaned; and

a type of vehicle assembly being cleaned.

5. The degreaser tank according to claim 4 , wherein the flushing operation is engaged for a period of from about 10 to about 20 seconds about four times per hour.

6. The degreaser tank according to claim 2 , further comprising a drain header pipe with an automated valve, wherein the drain header pipe is in fluid communication with a plurality of drain ports from the plurality of debris removal flushing stations.

7. The degreaser tank according to claim 6 , further comprising a pump and filter in fluid communication with the drain header pipe, the pump and filter configured to filter the debris from the degreaser and return a filtered degreaser to the holding tank via a plurality of supply lines of the plurality of debris removal flushing stations.

8. The degreaser tank according to claim 7 , further comprising a supply header pipe providing return fluid communication between the pump and the plurality of supply lines.

9. The degreaser tank according to claim 1 , further comprising a collection chute coupled to an interior of the holding tank and configured to collect and direct debris from a collection area adjacent an interior side wall of the holding tank, opposite the one or more electromagnets, to the drain port.

10. The degreaser tank according to claim 9 , wherein the supply line comprises a manifold with a plurality of spray nozzles configured to direct degreaser toward the debris from the collection area and down to the collection chute.

11. The degreaser tank according to claim 1 , wherein the one or more electromagnets are arranged in a row, coupled to the exterior of the holding tank.

12. A system for removing debris from a vehicle assembly in an alkaline degreaser bath, the system comprising:

a degreaser tank configured in shape and size to accommodate a degreasing cleaning of vehicle assemblies;

a conveyor system configured to selectively transfer the vehicle assemblies into and out of the degreaser tank;

a flushing system including a plurality of debris removal flushing stations located at side walls of the degreaser tank, each debris removal station comprising:

a set of electromagnets located adjacent to an exterior of the degreaser tank and configured to attract metal debris in the degreaser bath to a collection area at an interior wall, opposite the set of electromagnets;

a drain port located at a side wall, a distance below the set of electromagnets; and

a supply line located a distance above the set of electromagnets and configured to selectively provide a stream of alkaline degreaser toward debris, and directed to the drain port; and

a controller configured to engage each debris removal flushing station based on a predetermined cycle.

13. The system according to claim 12 , wherein each debris removal flushing station further comprises a collection chute coupled to an interior of the degreaser tank and configured to collect and direct debris from the collection area to the drain port.

14. The system according to claim 12 , wherein the controller is configured to engage a flushing operation of each debris removal flushing station using a predetermined cycle based on at least one of:

a production volume of vehicle assemblies being cleaned; and

a type of vehicle assembly being cleaned.

15. The system according to claim 12 , further comprising:

a drain header pipe in fluid communication with a plurality of the drain ports and including an automated drain header valve;

a supply header pipe in fluid communication with a plurality of supply lines; and

a pump and filter in fluid communication with the drain header pipe and the supply header pipe.

16. The system according to claim 15 , wherein the controller is configured to selectively:

operate the conveyor system;

engage and disengage the sets of electromagnets;

open and close the automated drain header valve; and

operate the pump to flush debris from the collection area to the drain ports.