DISA MAC Shot Blast Systems

DISA MAC Shot Blast Systems

DISA MAC Shot Blast Systems for Magnesium and Aluminium Castings Surface finishing of high-tech castings 06042 As light metal is heading forward with an increasing variety of new applications, more stringent demands are placed on the quality and performance of shot blast systems. Hence, foundries in general, and the automotive industry in particular, expect a high degree of process reliability and operational consistency to ensure meticulous finishing of their castings. DISA MAC shot blast systems offer the dependability and capacity necessary to meet these demands. They are fully automatic and very versatile. Consisting of single or double DISA MAC Shot Blast System cells, DISA MAC systems need less space and save costs. Intended for the targeted surface treatment of high-tech castings, the conceptual flexibility of DISA MAC systems facilitates integration into complete production plants. They also feature pushbutton-controlled blast cleaning for different types of specific castings. Range of applications DISA MAC systems are primarily designed for deburring and surface finishing of aluminium and magnesium castings. Critical areas and complex internal passages are perfectly cleaned. 2

High Cleaning Efficiency and Maximum Utilisation of the Infrastructure System configuration DISA MAC shot blast systems work in combination with an industrial robot equipped with a double manipulator assembly, that handles the castings. Handling includes loading, unloading, and shot evacuation. The approximate hourly throughput is 200 castings in single cell mode, depending on their complexity. The concept offers the following advantages: Simultaneous operations: During shot blasting, other processes, such as shot evacuation, pickup or delivery of the castings, etc., can be run simultaneously. Operation overlap and the double manipulator assembly serve to shorten overall cycle times and allow for extending individual cycle phases, such as the blasting time. Manipulator tools and robot are not exposed to the blasting stream. This minimizes wear and dynamic load. The shot-blast machine is equipped with simple access doors provided with simple sealing elements. A perfect team: Shot blast machine and robot form one single unit (robot and one or two DISA MAC systems) A) Sequence of simple consecutive operations: Loading Shot blasting Shot removal Unloading Delivery/pickup End of cycle B) Simultaneous operations (DISA MAC): Robot Unloading/loading External shot removal Delivery/pickup Unloading/loading External shot removal Delivery/pickup Shot blast machine Unloading/loading Shot blasting Unloading/loading Shot blasting End of cycle End of cycle C) Simultaneous double operations (2 x DISA MAC): Robot Unloading/loading1 Delivery1/pickup 2 Unloading/loading2 Delivery 2/pickup 1 Unloading/loading1 Delivery1/pickup 2 Shot blast machine 1 Unloading/loading1 Shot blasting1 Intern.shot removal 1 Unloading/loading1 Shot blasting1 Shot blast machine 2 Shot blasting 2 Intern.shot removal2 Unloading/loading 2 Shot blasting 2 Intern.shot removal2 Result: Maximum utilisation and protection of all structural elements and machine components help to reduce running costs. End of cycle 2 End of cycle 1 End of cycle 2 3

DISA MAC Manipulator and Shot Blast Machine Optimised blast cleaning to suit specific types of castings The heart of the machine is the shot blast housing with three position options for 2 or 3 blast wheels. The unit comprises a manipulatortype holder with two clamping arms one stationary and one moving to clamp the work-piece. Self-adjusting pressure springs firmly hold the work-piece in place and retain it even during a power failure. Replacement of the wear-resistant clamping and gripping tools is fast and simple. In the manipulator-type holder the work-piece rotates around two axes at the same time. Individually controlled cycle speeds and programmable swinging and stopping motions ensure unvarying precision and repeatability of the different cycle phases and the cleaning effect, further, continuous removal of shot from cavities and internal passages. The blast wheels can be arranged in three positions. Result: Maximum work-piece mobility and distinct work-piece specific blast finishing. MAC MOVE All-round flexibility in 2 axes 06075 06070 06071 Loading and unloading position The double manipulator assembly permits loading and unloading within seconds 4

An All-round Perfect Surface Finish The operating cycle The robot with the double manipulator assembly, holding an uncleaned work-piece, moves into the machine. It then seizes a cleaned work-piece and moves it out of the working area of the manipulator. The manipulator can then be loaded with an uncleaned work-piece. The access doors of the machine close as soon as the robot arm has retracted. The uncleaned part undergoes shot blasting while shot is continuously removed from its internal passages. The work-piece fixed in the manipulator rotates around its longitudinal and transverse axes in front of the blast wheels for thorough shot blasting of all surfaces and internal passages. Servomotors and rotary encoders control the exact position of the work-piece. Rotational speeds are set to meet individual finishing requirements. Residual shot can be evacuated inside or outside the machine. The cleaned work-piece is placed on a conveyor. Advantages of the system Selective exposure to the blasting stream for maximum blasting effect and energy efficiency Targeted blasting of critical surfaces, cavities and internal areas Reduced shot consumption, minimized wear, lower maintenance cost Pushbutton-controlled programming from the operator panel Complete shot removal inside or outside the machine Shot blasting compartment tightly sealed off by sliding doors The DISA blast wheels 2 or 3 blast wheels are used for blast cleaning. DISA blast wheels are renowned for high capacity and maximum energy efficiency. Abrasive feed and dosing can be controlled from the operator panel as required. The abrasive is mechanically pre-accelerated and delivered to the throwing blades in a continuous stream. This ensures optimal utilisation of the power of the drive motors. 1 Throwing blade 2 Opening (slot) 3 Control cage 4 Accelerator (impeller) Cross-sectional view of a blast wheel 06076 06077 06078 06073 Rotation around the longitudinal axis of work-piece......simultaneous clockwise or anti-clockwise rotation 5

DISA Shot Blast Systems Ease of Maintenance, Reliability and Operational Safety The compact, space-saving components and structure of DISA shot blast system facilitate fast on-site assembly and integration into existing production plants. All components, such as the shot blasting chamber, the blast wheels, and the manipulator, consist of carefully selected, wearresistant materials to ensure long service life. DISA blast cleaning systems have exceptional design features, such as specially selected protective lining to shield the blasting chamber from abrasive impingement. Close manufacturing tolerances allow for fast installation and removal of wear parts. Only original DISA wear parts and spare parts made of high-quality material are fully compatible with DISA shot blast systems and are tailored to suit specific applications. Integrated platforms and easy access serve to facilitate maintenance work. The system can be run without any operating personnel. Only periodic inspections are required. 06042 06045 06068 The system is designed to accommodate specific requirements for the shot blasting of aluminium and magnesium castings. The pneumatic separation system, for instance, is situated underneath the shot blasting chamber to prevent metallic dust accumulation. In combination with an optional wet filter the system design complies with prevailing explosion proof guidelines. 6

Technical Data All machine parts such as blast wheels, dust separation system, etc, are easily accessible The machine concept offers quick and simple loading and unloading through two front sliding doors The pneumatic separation system is located directly underneath the shot blasting chamber to prevent metallic dust accumulation Typ Workpieces Dimensions Max. part weight Cycle time (simple parts) Blast wheels Number Power rating Throwing speed Type of abrasive Power requirement 2) Dust separation capacity Dimensions (without robot) Length L Width B Heigth H DISA MAC-2-220 600 x320 x320 mm 15 kg ca. 18 sec 1) U 70 x 380 2or3 11 22 kw 36 73 m/sec aluminium or steel approx. 60 kw 10 000 m 3 /h 4 000 mm 3 400 mm 6 500 mm 1) Effective values determined in test runs 2) Without robot and dust separation system 7

DISA GROUP Founded in 1900, DISA is the world's leading supplier of foundry equipment and metal surface finishing systems. With factories, and sales and service offices in three continents and an extensive agent network, DISA serves international industrial manufacturers, foundries and metalworking industries with leading edge technology solutions, tailored to their specific needs. For more information please visit www.disagroup.com For illustrative purposes the DISA equipment may be shown without any warning labels and with some of the protective guards removed. The warning labels and guards must always be in place when the equipment is in use. The technical data are not binding. They are not warranted characteristics and are subject to change. Please consult Conditions of Supply stipulated in the relevant quotations. DISA Industrie AG, Switzerland, CH-8207 Schaffhausen, Tel +41 52 631 1717, Fax +41 52 631 4888, info.sh@disagroup.ch DISA Industrieanlagen GmbH, Germany, D-58099 Hagen, Tel +49 2331 965 3, Fax +49 2331 965 521, info.hagen@disagroup.com DISA Industrieanlagen GmbH, Germany, D-76229 Karlsruhe, Tel +49 721 4002 0, Fax +49 721 4002 260, info.karlsruhe@disagroup.com DISA Industries s.r.o., Czech Republic, Příbram I, CZ-261 01, Tel +420 318 479 111, Fax +420 318 479 333, info.pribram@disagroup.com DISA INDIA Ltd., India, Bangalore 560 066, Tel +91 80 2841 3301, Fax +91 80 2841 3315, bangalore@disagroup.com DISA Beijing Representative Office, P.R.China, Chaoyang District, Beijing 100022, Tel +86 10 5869 3381/82/83, Fax +86 10 5869 3380, disabj@disagroup.com DISA is a registered trademark; DISA Industrie AG, Switzerland, 2006; Printed in Germany by E+B; Reg. Nr. MAC 2028 1e 09 06 15