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VOL. 24 May ISSUE YEAR 2023
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in Vol. 24 - May Issue - Year 2023
Perfect Paint Preparation of Agricultural Equipment Components
The shot blast machine for the continuous blast-cleaning of welding assemblies is integrated into the overall manufacturing line. Manual touchup blasting of particularly complex surface areas can be done in a blast room located behind the outlet chamber of the shot blast machine. The thrown blast media from the blast room is transferred to the media cleaning system of the shot blast machine.

The shot blast machine for the continuous blast-cleaning of welding assemblies is integrated into the overall manufacturing line. Manual touchup blasting of particularly complex surface areas can be done in a blast room located behind the outlet chamber of the shot blast machine. The thrown blast media from the blast room is transferred to the media cleaning system of the shot blast machine.

The 12 Gamma 400G turbines are arranged in a circle around the blast chamber. Because of the curved design of the throwing blades, the shot blast process is particularly productive and energy-efficient. The turbine RPM is controlled by frequency inverters. The variable turbine speed and the automatic control of the media flow allows the precise adaptation of the blast-cleaning process to the different welding assemblies, which ensures optimal paint adhesion and prevents warping of thin-walled components.

The 12 Gamma 400G turbines are arranged in a circle around the blast chamber. Because of the curved design of the throwing blades, the shot blast process is particularly productive and energy-efficient. The turbine RPM is controlled by frequency inverters. The variable turbine speed and the automatic control of the media flow allows the precise adaptation of the blast-cleaning process to the different welding assemblies, which ensures optimal paint adhesion and prevents warping of thin-walled components.

In the Spotlight

For over 80 years, the privately owned Rösler Oberflächentechnik GmbH has been actively engaged in the field of surface preparation and surface finishing. As a leader in the global market, we offer a comprehensive portfolio of equipment, consumables and services around the mass finishing and shot blasting technologies for a wide spectrum of different industries. Our range of about 15,000 consumables, developed in our Customer Experience Centers and laboratories located all over the world, specifically serves our customers in resolving their individual finishing needs. Under the brand name AM Solutions, we offer numerous equipment solutions and services in the area of additive manufacturing/3D printing. Last-but-not-least, as our central training center, the Rösler Academy offers practical and hands-on seminars to the subjects mass finishing and shot blasting, lean management and additive manufacturing. In addition to the German manufacturing locations in Untermerzbach/Memmelsdorf and Bad Staffelstein/Hausen, the Rösler group has a global network of 15 locations and 150 sales agents.

Agricultural equipment is constantly exposed to tough climate and weather. For this reason, the optimal paint preparation is essential for the equipment to hold up under such tough conditions. A custom-engineered continuous feed spinner hanger blast machine RHBD-K 22/27-HD, installed in a new factory of a globally active manufacturer, is making a significant contribution to this goal. The shot blast machine is integrated into a fully automated manufacturing line, allowing the blast-cleaning of a variety of complex weldments which weigh up to two tons, prior to painting.

This Brazilian manufacturer supplies innovative agricultural machinery for a wide range of applications. For example, it is used for harvesting coffee beans and sugar cane as well as for seeding and cultivating all kinds of agricultural crops. The company is active in more than 100 countries. Reasons for this success are the excellent productivity and quality of the equipment as well as the continuous improvement of the manufacturing operation. It is not surprising that the new factory in Brazil is equipped with a fully automated and digitized manufacturing line. There, steel plates and profiles are cut, welded into complex constructions, shot blasted and painted in a continuous flow operation. Based on the tailor-made equipment concept, the technical implementation and the high equipment quality, the company had decided to purchase the continuous feed spinner hanger blast machine RHBD-K 22/27-HD made by Rösler. The work pieces are transported through the shot blast machine by the power & free conveyor system of the manufacturing line, which requires optimal coordination of the various interfaces in the manufacturing line. But thanks to the help by the colleagues at Rösler in Brazil, the whole project went very smoothly.

Energy-saving shot blast 
operation is integrated into the 
overall manufacturing process

After the welding operation, the components are transported through an inlet chamber into the actual blast chamber equipped with 12 Gamma 400G turbines, each with a drive power of 11kW. These innovative high-performance turbines of Rösler contain curved throwing blades in “Y” design. Compared to conventional turbines, the special blade design with optimal curvature increases the throwing speed significantly, resulting not only in an up to 20% higher blasting performance but also in significantly shorter cycle times.

Sophisticated equipment design allows more flexible shot blasting operation 

Because of the enormous diversities of work piece, the shot blast machine was designed to handle welding assemblies with dimensions of up to 10,000 × 2,000 × 2,500 mm (L × W × H) and weights of maximum 2,000kg. Some of the weldments have thick walls and are very sturdy, whereas others have thin walls and are delicate. To account for these differences and to consistently achieve the required preparation grade of Sa 2.5 as well as the specified surface roughness values, the turbine RPM is controlled by frequency inverters. This ensures optimal paint adhesion and prevents warping of the thin-walled components. The variable turbine speed and the automatic control of the media flow allow precise adaptation of the blast-cleaning process to the different welding assemblies. Selection of the work piece-specific shot blast programs is done at the master computer of the manufacturing line.
Behind the outlet chamber of the shot blast machine is a blast room that allows the manual touchup blasting of geometrically complex assemblies with undercuts and internal passages. Augers below the blast room floor transport the thrown blast media to the central media cleaning system. This eliminates the need for a separate media transport and cleaning system for the blast room.

Wear-resistant design ensures high equipment availability 

The customer was also impressed by the wear-resistant design of Rösler’s equipment. For example, the blast chamber is made of manganese steel and is protected by easily replaceable 10 mm thick wear liners, also made of manganese steel. Another plus is the fact that both sides of the throwing blades can be used, which practically doubles their usable life. The throwing blades can be replaced with a quick-change system without having to take the turbine apart.

For Information: 
Rösler Oberf lächentechnik GmbH
Vorstadt 1, 96190 Untermerzbach
Germany
Tel. +49.9533.924-802
Fax +49.9533.924-300
E-mail: d.hund@rosler.com