PRE-TREATMENT , SURFACE PREPARATION , DEGREASING & CLEANING
A finishing system that produces shorter cycle times and improved operational efficiency
Based on the surface finishes of the steel knifes that are required for the next manufacturing steps , the Rösler process engineers ran a series of processing trials in their test lab with various processing media and different process parameters . The best results were achieved with a Keramo-Finish process in a centrifugal disk finishing machine . This includes the use of a ceramic media with minimal abrasive characteristics in combination with a grinding and polishing paste and a cleaning compound with a distinct brightening effect . The new process allows the deburring and polishing of all knifes in one single machine . The rotary vibrator was no longer required , and the work piece handling was simplified . Moreover , depending on the work piece type , the new Keramo-Finish process reduces the processing times by 25 % to over 100 % and also allows bigger work piece batches . This helped to reduce the operational costs by around 10 % with , at the same time , greatly improved finishing results .
Fully automatic processing in a double batch system
The new double batch centrifugal disk finishing machine was perfectly integrated into the manufacturing flow at Gardena . Work piece specific processing programs stored in the PLC controller allow the targeted finishing of the various knife types .
After stamping , respectively , laser cutting the work pieces are collected in perforated metal bins . The operator utilises a swing crane to dump the raw knife components into a loading device that transfers them into a vibratory feed hopper . After the respective finishing program has been manually selected , the hopper automatically feeds a work piece batch into the work bowl for processing . After the preset finishing time the work bowl gently dumps the mix of finished work pieces and media onto a vibratory hopper from where the mix is transferred to a vibratory separation unit . There , with a precisely sized hole screen , the media and finished work pieces are separated from each other . At the same time , a special undersize media screen is discharging media that is no longer suitable for the finishing process . This guarantees a continuous high process stability .
While the media is returned into the work bowl , the finished knife blanks are transferred to the drying station filled with a maizecellulose product . The rotary dryer RT 550 Euro-DH is equipped with an innovative new heating system that guarantees not only fast , reliable and spot-free drying of the work pieces but also produces energy savings of up to 40 % compared to conventional rotary dryers . After completion of the drying cycle the knifes are transferred to another vibratory hopper that loads them into waiting small transport carriers made from plastic .
A fully automatic Z 1000 centrifuge is cleaning the process water and recycling it back to the mass finishing system for re-use in the finishing
The stamped and laser-cut knives are deburred and polished in a two-stage process in order to create optimal conditions for the next manufacturing step and to guarantee a long service life .
process . This helps save valuable resources . The drastically reduced water consumption , along with the innovative finishing solution and well-planned process controls ensure a sustainable and efficient operation of the new mass finishing system .
For more information please visit : www . rosler . com
The best results were achieved with a Keramo-Finish process in a centrifugal disk finishing machine . This includes the use of a ceramic media with minimal abrasive characteristics in combination with a grinding and polishing paste and a cleaning compound with a distinct brightening effect . Moreover , depending on the work piece type , the new Keramo-Finish process reduces the processing times by 25 % to over 100 %.
The finished knife blanks are transferred to the drying station filled with a maize-cellulose product . The rotary dryer RT 550 Euro-DH is equipped with an innovative new heating system that guarantees not only fast , reliable and spot-free drying of the work pieces but also produces energy savings of up to 40 %.
64 JUNE 2021 twitter : @ surfaceworldmag