PRE-TREATMENT , SURFACE PREPARATION , DEGREASING & CLEANING
geometry with its precisely calculated curvature produces a very high throwing speed with , at the same time , a lower energy consumption . This results in an up to 20 % higher shot blast performance . Moreover , because of their symmetric design both sides of the throwing blades can be used resulting in a two-fold increase of the usable blade life . Thanks to a special quick-change system blade changes can take place without having to dismount the turbine . The turbine placement ( position and angle ) was determined with a special simulation of the shot blast process . The highly focused blast pattern also contributes towards the high efficiency of the shot blasting process . In order to adapt the blast media throughput of up to 200 kg / min to the geometry of its steel components , Stelweld is utilizing three different shot blasting programs . The rotational speed of the turbines is adjusted by frequency inverters . This allows the precise control of the impact energy of the blast media on the work piece surface .
For optimum wear protection and , thus , a long equipment life , critical sections of the inlet and outlet chamber are fabricated from 6 mm thick manganese steel . The same material , this time 8 mm thick , is used for the blast chamber . Furthermore , the blast chamber is protected by overlapping , easy-to-replace wear plates made from high-strength materials . Sturdy rubber curtains in the inlet and outlet chamber , as well as the protection of gaps with multiple rubber seals and brushes , prevent any blast media spillage to the immediate environment . “ The turbines , the entire equipment design and the used materials guarantee a high uptime . This ensures a safe , trouble-free and energy-efficient operation ”, concludes the project manager .
Fully automatic , interlinked operation produces repeatable high quality
The power & free transport system transports the steel weldments , containing a QR code for the automatic selection of the respective shot blast program , to the shot blast machine . As soon as a trolley with one work piece has entered the inlet chamber , the double leaf doors are closing , and the turbines , the blast media return system and dust collector are starting automatically . During the shot blast process the work piece is passing through the blast chamber at a pre-defined speed . The 16 blast turbines ensure an intensive cleaning of all work piece areas with highly homogeneous and consistent shot blasting results . Two dropout boxes placed in the duct connection between shot blast machine and dust collector make sure that the generated dust is evacuated from the blast chamber , whereas re-usable blast media is returned into the shot blast machine .
The shot blast machine is accessible behind the outlet chamber . This allows the manual removal of residual blast media from the weldments , especially those with cup-shaped sections . An auger in the bottom returns the removed blast media to the media recycling and cleaning system consisting of two cascade air-wash separators . Subsequently the blast cleaned work pieces are transported to the KTL painting line .
Danuta Dobrzynska concludes : “ Compared to our previous manual shot blast operation the new shot blast machine achieves considerably better and much more consistent shot blast results in a much shorter time cycle . This allows us to employ our qualified personnel for more productive work , helping us to create more added value . Through savings in energy consumption and other operating costs the overall shot blasting operation has become considerably more economical ”.
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The special design of the 16 high performance Gamma 400G turbines with their curved throwing blades results in a significantly higher shot blast performance and a lower energy consumption . At the same time , compared to conventional turbines , the Gamma 400G turbines guarantee a two-fold increase of the usable life of the throwing blades .
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