Special Purpose Shot Peening Machine
Special Purpose Shot Peening Machine
This is continuously operating Rubber Belt Conveyor type Shot Peening Machine for Leaf Springs in special size. Machine entails high life Rubber Belt on which Leaf Spring are loaded through manganese fixtures. The stress side of Leaf Spring is Shot Peened by two powerful Blast Wheel Stations positioned at predetermined peening angle. Machine entails and comply all requirement of Shot Peening Standards.
‘Surfex’ Airless Shot Blasting Machine / Peening Machine for Leaf Spring
“Surfex” Airless Shot Peening Machine for Leaf Springs with Pulsejet Type Dry Dust Collector Unit, CFS Separator, Abrasive Replenisher, Time Clock, Electrical & Control Panel complete.
GENERAL SPECIFICATION OF THE MACHINE :
Leaf spring is placed up side down on belt conveyor on guide fixtures provided by customer which guides the spring, then it moves inside the blast chamber where it is blasted. .
Operating principle :
The machine is equipped with Blast Cabinet having inlet and outlet vestibules. The machine is provided with Chain Conveyor System for loading leaf spring on special hard fixture mounted on chain conveyor. The machine is provided with one/two powerful blast station for shot blasting / peening application. The machine is equipped with various accessories like Shot replenisher, Shot classifier and Shot separator for shot peening application. Magna Valve can also be provided for measuring shot flow rate and for controlling velocity of shot VFD drive is provided to Blast wheel unit. The spring are loaded on conveyor and pass into blast chamber for shot blasting / shot peening application. The shot blasted/shot peened springs come out from outlet vestibules. The operation of machine is continuous. The machine is provided with efficient Dust Collection System.
Blasting Cabinet :
The Blast Cabinet is fabricated from 6-8-10 mm thick heavy duty prime quality mild steel plates in welded construction and engineered suitably for strength and rigidity. The Vestibules are fabricated with 6 mm thick steel plate.
Blast Cabinet Liners :
The entire work cabinet is lined with 10 mm Mn. Steel overlapping tile. As and when these liners are worn out, the worn out liners are only to be replaced. The vestibule is rubber lined. .
Blast Wheel Assembly :
2 Nos. of Blast Wheel Stations, Size 25RLM195 (19 ½” x 2 ½”) with RADAIOLOC MECHANISM are mounted on 20 mm thick heavy duty prime quality steel plate and strategically around the cabinet and the pass line of the work. All blast wheels are arranged to blast at an angle with the line of job movement. The unit consists of fabricated steel casing having installation of different alloy steel liners, rotor, blades, control cage, impeller and feed spout. The rotor is made out of EN grade material duly hardened. The drive system of Blast wheel (Rotor) entails a set of self lubricated and self aligning pedestal bearings. The rotor is dynamically balanced. The drive shaft of blast wheel is made out of EN grade material and duly precision grinded to the finest accuracy. The fabricated casing of blast wheel assembly can be easily opened up through Bolts/Levers for examination of various liners and parts of wheel assembly. Individual ammeter is provided on control panel to indicate abrasive flow rate / loading of turbine in terms of current loading on ammeter..
A vestibule extends beyond the work entrance slot of the blast cabinet. The entrance vestibule is fabricated from 6 mm thick steel plates and combined with two set of hanging rubber seals. The spent abrasive trapped within the entrance vestibule is returned to the main abrasive system through hopper.
A Photo Electric Sensor is provided near inlet vestibule. The blast wheel will start only when job move into the vestibule. .
Abrasive Separator, Rotary Screen & Storage Hopper
The rotor of blast wheel assembly unit fires down the abrasive on the component moving on conveyor. The spent abrasive falls into hopper of the cabinet. The abrasive from hopper slides down to the screw conveyors that transfer them to the boot of the bucket elevator. These shots are elevated to the desired height with the help of buckets mounted on rubber belt.
The separator is COMPENSATING FLOW STRAIGHT (CFS) AIR WASH TYPE. A rotary screen is housed within the separator. Oversize contaminants and the media mixture are discharged from the head section of the bucket elevator into the rotary screen by means of an upper screw conveyor. The trashes will be directed by the internal screw flight to a trash and their currents remove the contaminants. The dust and useless fines will be air borne to an expansion chamber from where coarse material will drop into a refuse hopper and thereafter to the floor level through drain tubing and dribble valve control. The fine dust particles will be conveyed through vent piping to the dust collector.
The usable abrasives are transferred into the storage hopper for recirculation purpose. The abrasive from the storage hopper are transferred into blast wheel unit through feed gates. These gates are enclosing to reduce noise within 80-85 dB. The rotational movement of impeller constantly accelerates the incoming abrasives and feed them to the blades of rotor. An electro pneumatic valve operated by pneumatic cylinder and solenoid valve regulates the flow of abrasive to the blast wheel unit. The abrasive at high velocity are thrown by rotor on to the job.
The flow of abrasive to the wheel is controlled by specially designed dribble valve, which is mounted before the storage hopper. The valve is opened and closed with an air cylinder, which is actuated electrically by a 4-way solenoid pneumatic valve, consuming a few Cfm. Of compressed air at 80 psi. .
“Surfex” Hy-Pulse Jet Type Dust Collection System :
Surfex’ Hy-Pulse Jet Dust Collector of 3000 Cfm. with filter cloth area of 48 sq. mtrs. with polyester type non woven bag. Superior quality of fabric is used for making bags. The dust collector is pulsejet type and is self cleaning. The dust laden enters the dust collector housing through side inlet and passes through into settling, equalizing compartments expansion in the compartment takes place the air velocity drops and the flow is distributed over the entire setting area. The air then flows up and away from the storage hopper and causing the heavier dust particles to settle. The finer particle will move upwards into the filter bags. The air passes through the tubes to the atmosphere by means of exhaust fan mounted on the ground.
The bags are sequentially cleaned by back flushing with air from the clean air plenum. This momentarily air flow reversal is induced by shot bursts of compressed air released by fast acting, high flow diaphragm valves controlled by solenoid pilot valves which are operated one at a time by the control box.
Since only one row cleaned at a time, the unit continues to collect dust even as filter elements are cleaned.
Compressed air at a pressure of 90 to 105 psig. is required. Air must be relatively free of moisture and oil.
The dust is collected in the tray of the dust collector. The trays are taken out periodically and emptied. The filter bags are made out of spun bonded polyester. The blower unit of dust collector of dynamically balanced. The dust collector is fabricated in modular design and all the joints are sealed with high quality sealing compound.
Exhaust fan is designed with backward curved blades fan driven by 15 HP V-belt drives.
Belt Conveyor :
Special 5 Ply rubber perforated belt is provided to load leaf springs, this is powered by 2 HP geared motor controlled by variable pulley drive, speed of conveyor can be adjusted upto 3 mtrs./min..
Control Panel :
An independent control panel having the latest control system is provided. The digital ammeter and voltmeter are fitted for instant and accurate reading. The various timers of Reputed make are provided and interlocked. It also entails contactors, relays, push buttons, main isolation switch and inbuilt single phase preventor, overload protection, indicating lamps etc. Various safety features are inbuilt in the system like blast wheel motor will not operate if door is opened.
All Starters upto 12.5 HP will be Direct on the Line (DOL) and all Starters above will be Star Delta Types. All internal panel wiring is complete and the panel will be fitted with a mains isolators switch voltmeter and an ammeter
Inside and outside surface of equipments will be brush cleaned and given two coats of Epoxy Primer. Final coat on exterior of the system is PU paint Air Drying, Shade: Tata Green Shaded and electric line channel is Red Enameled and all the guards of motors are Yellow Enameled.