Shot peening system features high uptime and easy maintenance
A manufacturer of spare parts for gearboxes and differentials used in commercial vehicles turned to Rosler for the supply of a custom engineered shot peening system. Rosler engineered a fully automatic shot peening system capable of processing a wide range of gears and shafts with a high degree of process stability.
The gearboxes and differentials in commercial vehicles are exposed to extremely high loads. Until recently, a supplier of spare parts for such drivetrains was using a shot peening job shop to extend the service life of parts, including gears and shafts. Increasing quality requirements and production volumes by its customers prompted the company to bring the shot peening operation in-house.
Rosler’s custom engineered shot peening system, RWT13-2-S, allows for fully automatic shot blasting of gears and shafts with diameters as large as 500 mm (20”), heights up to 550 mm (22”) and weights of up to 60 kg (132 lbs.). The machine design is based on a proven swing table principle with two (2) separate chambers. This equipment concept minimizes non-productive times, because one work piece can be loaded/unloaded in one chamber, while another work piece is shot peened in the other chamber. For this reason the RWT can easily process 30 parts per hour.
Blast nozzles that can be easily adapted to different work pieces
Featuring a 6-nozzle blast unit, with horizontal and vertical movement, the Rosler shot peening system can be easily adjusted and produces excellent and repeatable peening results irrespective of work piece shape and size. For surface areas with angled gear teeth, the blast nozzles can be tilted from 0 to 90° allowing for the perfect adaptation of the blast stream to the surface contours. Depending on the processed work piece type, the blast media is thrown at the rotating gear or shaft with a pressure of one to six bars (14 to 90 psi). Since parameters like nozzle position and pressure are stored in the PLC, they can be automatically called off for the various work pieces. Overall, up to 30 processing programs can be stored in the system controls, a portable operator panel along with easy access to the blast chamber, help to facilitate programming tasks. The RWT also allows quick access to all critical machine components for easy maintenance.
Multiple system controls for high process safety
A dual pressure vessel allows for an uninterrupted and consistent shot peening operation. A sensor in the lower vessel monitors the blast media fill level. As soon as the preset minimum level is reached, the lower vessel automatically receives media from the upper vessel, which in turn is replenished from the media storage hopper.
Another safety feature is the media dosing system that controls the media flow rate making sure that the peening results are consistent and absolutely repeatable. In addition, sensors placed in the compressed air supply hose monitor the compressed air supply to the individual nozzles. Finally, the operating pressure of the peening system is continuously checked. If the pressure deviates from the set value, the system automatically shuts down.
To ensure that the work pieces turn, the rotation control sensor is positioned directly at the work piece-clamping device in the blast chamber rather than at the drive shaft of the rotational table. For easy operation of the shot peening system all process parameters and system components are displayed in an intuitive visualization on the portable operator panel.
Wear protection guarantees a high system uptime
The Rosler shot peening system offers excellent wear characteristics. The blast chamber is made from wear-resistant manganese steel and the direct blast zone is also lined with 25 mm (1”) thick, replaceable plates made from chilled cast iron. Placed outside of the blast chamber, the drive system for the rotation device is perfectly protected against any wear. All access doors are equipped with a special seal that is inflated after the door is closed, this prevents any media spillage to the outside.