DS and DV Manipulator Systems

DS and DV Manipulator Shot Blast Systems

Delivery:

18 weeks +

Technology:

Wheelblast

Application:

Cleaning, Corrosion Removal, Deburring, Deflashing, Rust and Heat Scale Removal

Industry:

Foundry/ Forge

Process:

In-line

Key Benefits

Fully automatic sequence of operations, including loading and unloading of workpieces

Automatic blast cleaning of castings of different shapes and sizes without the need for re-tooling

Optimised abrasive energy efficiency minimises wear of machine parts

High processing capacity

Features

  • Shot removal inside the machine and during the operating cycle. Less abrasive discharged with the clean workpieces
  • Programmable manipulator motions (rotating, swinging, stopping) for targeted cleaning of critical surfaces and internal passages

Applications

  • Blast cleaning, descaling and shot peening of gear housings, cylinder blocks and heads, crankshafts, intake manifolds, other serial parts in cast iron or aluminium

High Performance and Versatile Applications

Wheelabrator’s flexible and high performance manipulator shot blast systems are capable of handling components of different shapes and sizes without the need for re-tooling. These systems deliver outstanding performance due to their high process capacity and excellent cleaning efficiency.

Clever Workpiece Handling, Optimisation of Workflow, Powerful and Effective

A variety of basic machine models are available to suit specific applications.

  • Systems with manipulator grippers for desanding, descaling and surface finishing of gearboxes, crankcases, cylinder heads, and other cast iron and light metal components (green sand, gravity and pressure die castings)
  • Systems fitted with rotating support shafts for desanding, descaling and shot peening of crankshafts, and other rotational parts

Six basic models, each of modular design, provide the flexibility necessary to cover a wide spectrum of requirements with regard to output, floor space, and material handling arrangements. Manipulator shot blast systems can be combined with air blast stations and are suitable for integration into automatic fettling lines.

These shot blast systems are either fitted with rotating support shafts or with flexible manipulator grippers to pick up the workpieces and transport them through the shot blast machine. The gripper
tools automatically adapt to the shape of a particular workpiece and are able to accommodate one or more parts.

Automatic and Flexible Blast Cleaning of Complicated Parts

A loading device or an industrial robot places the uncleaned workpieces on support shafts or in the manipulator where they are firmly held. Fully automatic shot blast systems can be equipped with sensors for part identification and workpiece-specific control of the blast parameters (blast time, shot quantity, throwing speed, workpiece movement during blasting, number of activated blast wheels, shot removal time, etc.). The selective placement of the workpieces ensures optimal and continuous exposure to the blast stream, whilst delivering the best shot energy efficiency and minimal wear of machine parts.

DV4 Manipulator System Animation

Smart Loading / Unloading Techniques

Fully automated production systems call for intelligent materials handling solutions to deliver:

  • Logically coordinated production sequences without the need for multiple handling and buffer storage space 
  • Close monitoring of all successive operations
  • Elimination of manual operations at delivery, loading, unloading, transfer points and interfaces between machines

Robots and mechanical devices are available to accomplish these tasks. However, the choice of the appropriate equipment must primarily be based on cost/benefit considerations, infrastructure and customer individual preferences.

Mechanical Loading / Unloading Devices

These devices offer practical and costsaving solutions for machines in factories with restricted floor space. Continuous throughput machines for workpieces weighing more than 250 kg each, or machines loaded on the front side and unloaded from the rear side, are typical applications for such devices. Their ability to handle different workpieces of diverse shapes is an added advantage.

Optimisation of Workflow - Industrial Robots

Industrial robots are generally used in combination with machines operating with short cycle times to process workpieces. The robots can be programmed to carry the workpieces reliably along complex pre-defined paths and to move them into the required positions. High precision and motion repeatability, and flexibility when changing from one task to the next, are important advantages of industrial robots. They can also be used for shot evacuation outside the machine. For systems comprising autonomous cells for blast cleaning, deburring, trimming, and grinding of workpieces, robots can serve to link these individual process stages, helping to reduce unproductive downtime and operating cost.

 

 

DS 1 Shot Blast Systems: Compact and Versatile

The shot blast machines of the DS 1 series are designed for the treatment of cast iron, light metal and forged workpieces. The machines feature a combined shot blast and shot removal chamber.

Depending on the particular application, they can be fitted with a manipulator gripper or with rotational support shafts to receive rotating parts, such as crankshafts, etc. In accordance with the workflow, the machines can be loaded and unloaded at the front or, alternatively be loaded at the front and unloaded from the rear with the help of a robot or a loading device. In most cases the machines can process the workpieces in pairs to increase production output. Programmable motion sequences of the manipulators (rotating, swinging, stopping) ascertain precisely targeted shot impingement on even the most critical workpiece surfaces. The high-tech control system ensures that parts are processed according to preset parameters, such as blast time, shot quantity, throwing speed, number of activated blast wheels, shot removal time, etc.

The compact design of the machines offers ample flexibility with regard to layout and production flow to the user. Moreover, the machines can easily be integrated in existing installations.

DV Series: Simultaneous Shot Blasting

DV shot blast systems are exclusively used for the treatment of cast or forged iron components. They are equipped with 4, 8 or 12 blast wheels and 2 or 4 manipulator grippers or the corresponding number of support shafts.

These systems can run between 20 and 80 operating cycles to process up to 160 parts per hour. The size and load capacity of the grippers or shafts is chosen according to workpiece type.

In DV shot blast systems, loading / unloading and shot blasting are performed simultaneously. The complete shot blasting of complex workpiece interiors occurs in one operating cycle inside the machine.

A robot or loading device loads and unloads the workpieces at the front of the machine. The system offers the possibility of processing parts in pairs. Programmable manipulator gripper motions (rotating, swinging, stopping) allow for targeted treatment of critical surfaces.

The space-saving design of the system facilitates its integration into existing plants. It’s design concept allows users to coordinate the shot blasting machine with existing peripheral equipment and
handling facilities enabling a high degree of automation to be achieved.

DS 4 / DS 5 / DS 6 / DS 8 Shot Blast Systems

The DS 4-,-5, -6, and DS 8 series offer a wide range of concept options and meet a variety of output and quality expectations. They allow workpieces to be processed in several compartments at the same time.

Among the typical treatment applications of these high capacity systems are components for the automotive industry, including desanding, descaling and shot peening of rotational parts.

DS 4 machines with 4 compartments are designed for the surface treatment of light metal parts and rotational parts. DS 5, -6, and -8 systems are equipped with 5, 6, and 8 compartments, and are used for the treatment of iron components. Loading and unloading are carried out during the operation of the shot blast machines, by robots or mechanical loading and unloading devices. This enables users to minimise downtime and increase production output. It is also possible to treat the workpieces in pairs. These machines have between 4 and 12 blast wheels and 4, 5, 6 or 8 manipulator grippers. Size and load capacity of the grippers will be selected based on individual requirements.

Universal Wheel

The blast wheel is the heart of the blasting machine, as the choice of blast wheel determines the power output and the economics. 

This machine is fitted with U70x500 Universal (indirect drive) shot blast wheels as standard. The Wheels are highly flexible, compact and have rotation in both directions. They provide perfect blast cleaning results and highly convenient servicing features.

 The U Blast Wheels are high capacity blast wheels with maximum energy efficiency. Their rugged design means that maintenance is easy, and the special and highly wear resistant cast alloy liners ensure minimum wear and maximum service life of the blast wheel.

What Next?

We provide high quality, long lasting replacement parts.
As the largest distributor of replacement parts in the industry we can deliver globally in the shortest timescales to prevent you having to have a large inventory stock on site or breaks in production.

Parts and Consumables

Machine Upgrades

We will continually inform you of the latest technology upgrades so that you can decide whether you want to have the latest technology added to your maintenance for optimum life.

Equipment Modernisation

#PerfectMatch
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