Automation Part 7 – The Top 3 Mass Finishing and Shot Blasting Machines
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Rosler understands that automating aspects of your mass finishing and shot blasting processes has never been more critical.
As we have learned during recent world events, outside factors can have a significant impact on your ability to maintain a largely manual process. Though automated mass finishing and shot blasting machinery does require some human intervention, it can often be operated with a minimal headcount and limited human contact.
In previous blogs, we have explored how an automated-first posture can help you to gain significant efficiencies, lower costs, and increase your competitive advantage. We have also looked at the balance between automation and the environment and have discussed ways that you can mitigate environmental impacts of operating automated mass finishing and shot blasting machinery.
We now conclude our Automation Blog Series with best practice examples of automated mass finishing and shot blasting machines Rosler offers and the associated accessories and components available to help in building your next-generation automated processes.
Mass Finishing
- Automated Dual Rosler Drag Finishing Systems for Tool Bodies
This drag finishing system is particularly useful for finishing of milling tool holders where work pieces are de-oiled, deburred, smoothed, and polished. Work stations equipped with drag finishing equipment feature special quick-connect couplings to expedite the work of robots to load and unload work pieces.
Automated Dual Rosler Drag Finishing System pictogram
As seen in the pictogram, a robot picks up the work pieces from a staging pallet and transfers them to the first R 6/1000 SF machine in a precise location with an accuracy of 4/1000th of an inch (= 0.1 mm). Work pieces are then moved to a second R 6/1000 SF for smoothing and polishing before the robot moves pieces to a second staging pallet upon completion.
Automated R 6/1000 SF Drag Finishing System
This fully automated process is complemented by the Rosler Z1000 centrifuge for water cleaning and recycling. In order for precise finishing results, the work surface must be smooth, clean, and free of nicking and scratching.
Walter Tools CNC milling cutter head processed by the Rosler Dual Drag Finishing System
2. Linked Dual Rosler Centrifugal Disk Finishing Systems
Also known as the FKS 15.1 A2, this system is used in the finishing of special stampings with a focus on the de-oiling, deburring, and edge radiusing of disk springs, rings, and washers.
An example of work pieces processed by the Rosler Automated FKS System
With a fully automated operation, the system handles the complete loading, unloading, transporting, washing, and drying of parts and media mixes – concluding with the backfilling of the finished parts into waiting bins.
Linked Dual Rosler Centrifugal Disk Finishing System pictogram
This process ensures batch integrity as long as individual batches are not mixed up in the screening machine and are completely oil-free with a defined edge radius prior to entering the machine.
Automated FKS System also known as a Linked Dual Centrifugal Disk Finishing System
3. Rosler Linear Continuous Flow Vibratory Systems for Metal Parts
Rosler’s linear continuous flow vibratory systems manage the de-oiling and deburring process for a wide variety of stampings.
Work Pieces processed by a Rosler Linear Continuous Flow Vibratory System
In the example below, parts are dumped en masse into the vibratory feed hopper by a forklift equipped with a fork rotator. The machine then places the empty part bin behind the hot air drier while the work pieces progress through the system in a fully automated manner.
Rosler Linear Continuous Flow Vibratory System pictogram
Batches must be processed separately, and parts must be free of oil for maximum throughput.
Automated Rosler In-line DA System with parts loader and dryer
Shot Blasting
- Rosler RROB Roboblaster for Cylinder Heads
Rosler RROB Roboblaster with parts transportation system
Able to precisely clean, de-sand, and deburr cast aluminum components, Rosler’s RROB Roboblaster is ideal for cylinder heads.
Cylinder head processed by the Rosler RROB Roboblaster
Its process begins when raw cylinder head castings are staged on two roller conveyors connected with a 90-degree turntable. Next, a robot equipped with a rotating device selects individual castings and suspends them into the machine. As the robot rotates the raw cylinder head, the blasting process takes place on all exposed surfaces. Finally, the robot places the finished cylinder heads into a screen drum for shaking out of residual blast media.
Rosler RROB Roboblaster pictogram
2. Rosler RMBC 8.2 Tumblast Machine for Forged Components
Part of Rosler’s Tumblast offerings, the RMBC 8.2 machine is particularly useful in descaling a wide variety of different forgings, including high volumes of bevel gears, in preparation for machining.
Work pieces processed by the Rosler RMBC 8.2 Tumblast Machine
An operator places two bins with raw parts into the skip loader after which empty bins are placed on a chain conveyor. Following shot blasting within the machine, finished parts are dumped onto a vibratory hopper, which tumbles, then automatically returns the finished parts into the waiting bins on the chain conveyor.
Rosler RMBC 8.2 Tumblast Machine pictogram
As with other automated machinery, it is critical to load distinct batches individually and to ensure the parts are free of scale.
Rosler Automated RMBC 8.2 Tumble Belt Blast System with parts loading and unloading
3. Rosler RKWS 3 x 4 for Blast Cleaning of Crankshafts
Rosler Automated RWKS 3 x 4 Cranksaft Blaster with robotic parts loading
This particular model of the RKWS shot blast machine is equipped with three blast chambers arranged in a circle; each chamber is outfitted with four Gamma G blast turbines to accomplish the descaling process for crankshafts and other work pieces.
Crankshafts before and after processing by RKWS
A robot handles the loading and unloading of the parts, making this process fully automated. It’s important to note that piece weight is limited to a minimum of 14 lbs (6 kg) and maximum of 40 lbs (18 kg); after blasting the surface must be Sa 3 (white metal, no remaining traces of mill scale or rust allowed).
Rosler Automated RWKS 3 x 4 Cranksaft Blaster with robotic parts loading
The Rosler Way
By appropriately outfitting your operation with the right selection of automated mass finishing and shot blasting systems, you can be assured of gaining efficiencies and benefits that will help you maintain your competitive advantage.
At Rosler, more than eight decades of experience and a constant drive to harness the latest advances allow us to design and manufacture innovative mass finishing and shot blasting solutions to fit your unique needs. Contact us today to learn how we can improve and automate your finishing system.
The complete Automation Series includes:
- Part 1 – How Robots are Improving Mass Finishing and Shot Blasting Processes.
- Part 2 – Why Automation is Beneficial for Your Business.
- Part 3 – What Problems Do You Want to Solve?
- Part 4 – How Do I Select the Right Machine and Consumables?
- Part 5 – What Automation Hardware is Available?
- Part 6 – Environmental Considerations of Automation.
- Part 7 – The Top 3 Mass Finishing and Shot Blasting Machines.
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