Steel Structure Roller Conveyor Shot Blasting Machine
1. Brief Profile
The Steel Structure Roller Conveyor Shot Blasting Machine is a highly specialized and efficient industrial equipment designed for the surface treatment of steel structural components. It integrates advanced shot blasting technology with a roller conveyor system, creating a seamless and automated process that removes rust, scale, oxide layers, oil, and other contaminants from the surface of steel structures. This not only enhances the aesthetic appearance of the steel but also significantly improves its mechanical properties, such as fatigue resistance and adhesion for subsequent coating processes.
In the modern manufacturing and construction industries, the demand for high-quality steel structures is constantly rising. Whether it is for large-scale infrastructure projects like bridges, stadiums, and high-rise buildings, or for industrial equipment such as boilers, pressure vessels, and heavy machinery, the surface quality of steel components directly affects the overall performance, service life, and safety of the final product. The Steel Structure Roller Conveyor Shot Blasting Machine addresses this critical need by providing a reliable, high-throughput solution that meets strict industry standards and specifications.
Unlike traditional manual cleaning methods or other types of shot blasting machines, this equipment offers unique advantages. The roller conveyor system ensures continuous and stable transportation of steel workpieces, eliminating the need for manual handling and reducing labor costs and the risk of workplace injuries. The shot blasting process is highly controllable, with adjustable parameters such as shot flow rate, blasting speed, and conveyor speed, allowing it to adapt to a wide range of steel structure sizes, shapes, and surface conditions.
Moreover, the machine is designed with environmental protection and energy efficiency in mind. It is equipped with advanced dust collection systems that capture and filter the dust and debris generated during the shot blasting process, minimizing air pollution and ensuring compliance with environmental regulations. Energy-saving components, such as high-efficiency motors and optimized blast wheel designs, help reduce energy consumption, making the equipment more cost-effective and sustainable in the long run.
Over the years, with the continuous development of materials science, mechanical engineering, and automation technology, the Steel Structure Roller Conveyor Shot Blasting Machine has undergone significant upgrades. Modern models feature intelligent control systems, touch-screen interfaces, and remote monitoring capabilities, enabling operators to easily set up, adjust, and monitor the machine's performance in real-time. This not only improves operational efficiency but also ensures consistent and high-quality surface treatment results.
In summary, the Steel Structure Roller Conveyor Shot Blasting Machine is an indispensable piece of equipment in the steel processing industry. Its combination of advanced technology, automation, and environmental friendliness makes it a preferred choice for manufacturers and construction companies seeking to enhance the quality and reliability of their steel structures while optimizing production processes and reducing costs.
2. Application
The Steel Structure Roller Conveyor Shot Blasting Machine has a wide range of applications across various industries, thanks to its versatility, efficiency, and ability to handle different types of steel structural components. Below are some of the key application areas where this machine plays a crucial role:
2.1 Construction Industry
In the construction industry, steel structures are widely used in the construction of bridges, high-rise buildings, stadiums, airports, and other large-scale infrastructure projects. Before these steel structures are installed, they need to undergo surface treatment to remove rust, scale, and other contaminants that can weaken the structure over time. The Steel Structure Roller Conveyor Shot Blasting Machine is ideal for this purpose. It can handle long and heavy steel beams, columns, trusses, and plates, ensuring that their surfaces are clean and smooth. This not only improves the structural integrity of the steel components but also enhances the adhesion of paints, coatings, and anti-corrosion materials, extending the service life of the entire structure.
For example, in the construction of a bridge, the steel girders and deck plates need to be treated to prevent corrosion caused by exposure to moisture, saltwater (in coastal areas), and other environmental factors. The shot blasting machine efficiently removes any surface impurities, creating a rough surface profile that allows the anti-corrosion coating to bond firmly. This significantly reduces the risk of rust and corrosion, ensuring the bridge's safety and durability for decades.
2.2 Heavy Machinery Manufacturing
The heavy machinery manufacturing industry produces a wide range of equipment, such as excavators, bulldozers, cranes, and mining machinery. These machines are made up of large and heavy steel components that require high strength and durability. The surface treatment of these components is essential to ensure their performance and reliability. The Steel Structure Roller Conveyor Shot Blasting Machine is used to clean the surfaces of steel frames, chassis, and other structural parts of heavy machinery. By removing oxide layers, burrs, and other defects, the machine improves the surface quality of the components, making them more resistant to wear, impact, and corrosion. This not only extends the service life of the machinery but also reduces maintenance costs and downtime.
In the production of a crane, for instance, the steel boom and jib are critical components that bear heavy loads. The shot blasting process removes any surface contaminants and strengthens the surface of the steel, increasing its fatigue resistance. This ensures that the crane can operate safely and efficiently under heavy working conditions.
2.3 Boiler and Pressure Vessel Industry
Boilers and pressure vessels are used in power plants, chemical plants, and other industrial facilities to store and transport high-temperature and high-pressure fluids. The surface quality of the steel used in these equipment is of utmost importance, as any defects or contaminants can lead to leaks, explosions, and other serious safety hazards. The Steel Structure Roller Conveyor Shot Blasting Machine is used to clean the inner and outer surfaces of boiler shells, pressure vessel heads, and pipes. It removes rust, scale, and oil residues, ensuring that the surfaces are smooth and free from defects. This not only improves the safety performance of the boilers and pressure vessels but also enhances their heat transfer efficiency, reducing energy consumption.
In a power plant, for example, the boiler tubes are exposed to high temperatures and pressures. The shot blasting machine cleans the inner surfaces of the tubes, removing any scale or deposits that can reduce heat transfer. This helps the boiler operate more efficiently, generating more electricity while consuming less fuel.
2.4 Shipbuilding Industry
The shipbuilding industry relies heavily on steel structures for the construction of ships, offshore platforms, and other marine vessels. These steel components are exposed to harsh marine environments, including saltwater, humidity, and strong winds, which can cause severe corrosion. The Steel Structure Roller Conveyor Shot Blasting Machine is used to treat the steel plates, profiles, and components used in shipbuilding. It removes rust, mill scale, and other contaminants, preparing the surfaces for the application of anti-corrosion coatings and paints. This ensures that the ship's hull, deck, and other structural parts are protected from corrosion, extending the ship's service life and reducing maintenance costs.
For offshore platforms, which are constantly exposed to saltwater and harsh weather conditions, the shot blasting process is even more critical. The machine cleans the surfaces of the platform's steel legs, beams, and modules, ensuring that the anti-corrosion coatings adhere properly. This helps prevent corrosion and structural damage, ensuring the safety and reliability of the offshore platform.
2.5 Automotive and Railway Industries
In the automotive and railway industries, steel is used in the manufacturing of vehicle bodies, frames, and components. The surface treatment of these steel parts is essential to improve their appearance, corrosion resistance, and mechanical properties. The Steel Structure Roller Conveyor Shot Blasting Machine is used to clean the surfaces of large steel components such as automotive chassis frames and railway carriages. It removes burrs, oxide layers, and other defects, creating a smooth surface that is suitable for painting and coating. This not only enhances the aesthetic appeal of the vehicles but also improves their durability and safety.
In the production of railway carriages, for example, the steel body panels need to be treated to prevent corrosion caused by exposure to rain, snow, and other environmental factors. The shot blasting machine efficiently cleans the surfaces of the panels, ensuring that the paint adheres firmly. This extends the service life of the railway carriages and reduces the need for frequent maintenance.
In addition to the above industries, the Steel Structure Roller Conveyor Shot Blasting Machine is also used in the manufacturing of steel furniture, storage racks, and other steel products. Its ability to handle different sizes and shapes of steel components makes it a versatile and valuable equipment in various industrial sectors.
3. Features
The Steel Structure Roller Conveyor Shot Blasting Machine is equipped with a range of advanced features that set it apart from other surface treatment equipment. These features not only ensure efficient and high-quality surface treatment but also enhance the machine's reliability, safety, and ease of operation. Below are the key features of this machine:
3.1 High Efficiency and Throughput
One of the most prominent features of the Steel Structure Roller Conveyor Shot Blasting Machine is its high efficiency and throughput. The machine is designed with a powerful shot blasting system that consists of multiple high-performance blast wheels. These blast wheels are capable of projecting steel shots at high speeds (up to 80-100 m/s) and with high density, ensuring that the surface of the steel components is thoroughly cleaned in a short period of time.
The roller conveyor system, which is the core of the machine, operates continuously, transporting the steel workpieces through the shot blasting chamber at a adjustable speed. This allows for a steady flow of workpieces, minimizing downtime and maximizing production efficiency. Depending on the size and type of the steel components, the machine can handle a throughput of up to several tons per hour, making it suitable for large-scale production lines.
Moreover, the shot blasting chamber is designed with a optimized internal structure that ensures uniform coverage of the steel workpieces. The blast wheels are strategically positioned to cover all surfaces of the workpiece, including the top, bottom, sides, and edges. This eliminates any blind spots and ensures that every part of the workpiece receives the same level of cleaning, resulting in consistent and high-quality surface treatment.
3.2 Versatility and Adaptability
The Steel Structure Roller Conveyor Shot Blasting Machine is highly versatile and can adapt to a wide range of steel structural components. It can handle workpieces of different sizes, shapes, and weights, from small steel plates and profiles to large and heavy beams, columns, and trusses. The roller conveyor system is designed with adjustable roller spacing and height, allowing it to accommodate workpieces of various dimensions.
In addition, the machine's shot blasting parameters, such as shot flow rate, blast wheel speed, and conveyor speed, can be easily adjusted to meet the specific requirements of different workpieces. For example, for workpieces with a thick oxide layer, a higher shot flow rate and slower conveyor speed can be used to ensure thorough cleaning. For delicate workpieces that require a lighter surface treatment, a lower shot flow rate and faster conveyor speed can be selected. This versatility makes the machine suitable for a wide range of applications across different industries.
Furthermore, the machine can be customized with additional features to meet specific customer needs. For example, it can be equipped with a pre-heating system to remove moisture from the surface of the workpieces before shot blasting, or a post-treatment system such as a painting or coating unit to further enhance the surface properties of the steel components.
3.3 Advanced Dust Collection System
Environmental protection is a key consideration in modern industrial production, and the Steel Structure Roller Conveyor Shot Blasting Machine is designed with an advanced dust collection system to minimize air pollution. The machine generates a large amount of dust and debris during the shot blasting process, which can be harmful to the environment and the health of the operators. The dust collection system efficiently captures and filters this dust, ensuring that the exhaust air meets the national environmental protection standards.
The dust collection system typically consists of a cyclone separator, a bag filter, and a centrifugal fan. The cyclone separator first separates the large particles of dust and debris from the air, reducing the load on the bag filter. The bag filter then traps the fine particles of dust, ensuring that the air discharged from the machine is clean and free from harmful contaminants. The collected dust can be easily disposed of or recycled, depending on the specific requirements.
In addition, the shot blasting chamber is equipped with a sealing system to prevent dust leakage. The entrance and exit of the chamber are fitted with rubber curtains or brush seals that effectively block the escape of dust, ensuring a clean and safe working environment.
3.4 Durable and Reliable Construction
The Steel Structure Roller Conveyor Shot Blasting Machine is built to withstand the harsh conditions of industrial use, ensuring long-term durability and reliability. The main components of the machine, such as the shot blasting chamber, roller conveyor, and blast wheels, are made of high-quality materials that are resistant to wear, impact, and corrosion.
The shot blasting chamber is constructed from thick steel plates that are reinforced with steel ribs to withstand the high impact of the steel shots. The inner surface of the chamber is lined with wear-resistant materials such as manganese steel plates or rubber liners, which protect the chamber from abrasion and extend its service life.
The roller conveyor system consists of heavy-duty rollers that are made of high-carbon steel or alloy steel. These rollers are heat-treated to increase their hardness and wear resistance, ensuring that they can withstand the weight of the steel workpieces and the continuous operation of the machine. The bearings of the rollers are sealed and lubricated to prevent dust and debris from entering, reducing maintenance requirements and extending the service life of the rollers.
The blast wheels are the core components of the shot blasting system, and they are designed to be highly durable and efficient. The impellers and blades of the blast wheels are made of high-wear-resistant materials such as high-chromium cast iron or cemented carbide, which can withstand the high-speed impact of the steel shots. The blast wheels are also dynamically balanced to ensure smooth operation and reduce vibration, minimizing wear on the machine's other components.
3.5 Intelligent Control and Easy Operation
Modern Steel Structure Roller Conveyor Shot Blasting Machines are equipped with intelligent control systems that make operation easy and efficient. The control system typically features a touch-screen interface that allows operators to set up, adjust, and monitor the machine's parameters in real-time. Operators can easily input the workpiece dimensions, desired surface treatment quality, and production speed, and the control system will automatically adjust the shot flow rate, blast wheel speed, and conveyor speed to achieve the optimal results.
The control system also includes a range of safety interlocks and alarms to ensure the safety of the operators and the machine. For example, if the shot level in the shot hopper is too low, the machine will automatically stop and sound an alarm. If there is a jam in the roller conveyor, the control system will detect it and stop the machine to prevent damage.
In addition, the machine is equipped with remote monitoring capabilities, allowing maintenance personnel to monitor the machine's performance from a remote location. This enables timely detection of any potential issues and allows for quick troubleshooting, reducing downtime and improving the machine's availability.
3.6 Energy Efficiency
Energy efficiency is an important factor in reducing production costs and promoting sustainable development. The Steel Structure Roller Conveyor Shot Blasting Machine is designed with a range of energy-saving features that help reduce energy consumption.
The blast wheels are driven by high-efficiency motors that have a high power factor and low energy consumption. The design of the blast wheels is also optimized to minimize energy loss, ensuring that more of the motor's power is used to project the steel shots rather than being wasted as heat or noise.
The roller conveyor system is also designed to be energy-efficient. The rollers are mounted on low-friction bearings, reducing the power required to drive the conveyor. In addition, the conveyor speed can be adjusted according to the production requirements, allowing for optimal energy use.
Furthermore, the machine is equipped with a heat recovery system that captures the heat generated during the shot blasting process and uses it to preheat the incoming air or the workpieces. This not only reduces energy consumption but also improves the efficiency of the shot blasting process.
4. Main parts
The Steel Structure Roller Conveyor Shot Blasting Machine is composed of several key components that work together to achieve efficient and high-quality surface treatment of steel structural components. Each part plays a crucial role in the overall operation of the machine, and their proper functioning is essential to ensure the machine's performance, reliability, and safety. Below are the main parts of the machine:
4.1 Shot Blasting Chamber
The shot blasting chamber is the core part of the machine where the actual shot blasting process takes place. It is a closed, rigid structure that is designed to withstand the high impact of the steel shots and prevent dust and noise from escaping. The chamber is typically made of thick steel plates that are welded together to form a strong and durable structure. The inner surface of the chamber is lined with wear-resistant materials to protect it from abrasion caused by the steel shots. Common wear-resistant liners include manganese steel plates, rubber liners, and ceramic liners. These liners can be easily replaced when they become worn, extending the service life of the chamber.
The shot blasting chamber is equipped with multiple blast wheel assemblies that are strategically positioned to ensure uniform coverage of the steel workpieces. The number and position of the blast wheels depend on the size and type of the workpieces being treated. For example, a machine designed to treat large steel beams may have blast wheels mounted on the top, bottom, and sides of the chamber to cover all surfaces of the beam. The chamber also has an entrance and an exit that are fitted with sealing devices, such as rubber curtains or brush seals, to prevent dust leakage and ensure a clean working environment.
4.2 Roller Conveyor System
The roller conveyor system is responsible for transporting the steel workpieces through the shot blasting chamber. It consists of a series of rollers that are mounted on a rigid frame and driven by a motor and a transmission system. The rollers are made of high-quality steel that is heat-treated to increase their hardness and wear resistance. They are spaced at regular intervals to support the workpieces and ensure smooth transportation.
The roller conveyor system can be adjusted to accommodate workpieces of different sizes and weights. The roller spacing can be changed by adjusting the position of the roller supports, and the height of the conveyor can be adjusted using hydraulic or mechanical lifting devices. The speed of the conveyor is also adjustable, allowing operators to control the residence time of the workpieces in the shot blasting chamber. This ensures that the workpieces receive the optimal amount of shot blasting to achieve the desired surface quality.
The transmission system of the roller conveyor typically consists of a motor, a reducer, and a chain or belt drive. The motor provides the power to drive the rollers, and the reducer reduces the speed of the motor to the desired conveyor speed. The chain or belt drive transmits the power from the reducer to the rollers, ensuring that all rollers rotate at the same speed. The transmission system is designed to be reliable and efficient, with minimal maintenance requirements.
4.3 Blast Wheel Assemblies
The blast wheel assemblies are the core power units of the shot blasting system, responsible for accelerating and projecting steel shots onto the surface of the steel workpieces. Each blast wheel assembly consists of a motor, a blast wheel, an impeller, blades, a control cage, and a feed spout.
The motor provides the rotational power to drive the blast wheel. To ensure high efficiency and stable operation, the motor is typically a high-torque, variable-speed type that can be adjusted according to the required shot projection intensity. The blast wheel, which is connected directly to the motor shaft, rotates at high speeds (usually between 1500-3000 rpm) to generate the centrifugal force needed to accelerate the steel shots.
The impeller and blades are key components that determine the speed and direction of the shot projection. The impeller is a disc-shaped part with evenly distributed slots, and the blades are inserted into these slots. As the blast wheel rotates, the steel shots are fed into the center of the impeller through the feed spout. The centrifugal force pushes the shots outward along the blades, where they are accelerated to high velocities before being projected onto the workpiece surface. The shape and angle of the blades are carefully designed to optimize the shot trajectory and ensure uniform distribution of the shots across the workpiece.
The control cage, also known as the directional cage, is a ring-shaped component surrounding the impeller. It has adjustable vanes that control the direction of the shot flow. By adjusting the position of these vanes, operators can change the angle at which the shots are projected, allowing for precise targeting of specific areas of the workpiece. This is particularly useful for treating workpieces with complex shapes or hard-to-reach areas.
The feed spout is responsible for delivering the steel shots from the shot storage hopper to the blast wheel. It is designed to ensure a steady and uniform flow of shots, preventing clogs and ensuring consistent shot projection. Some advanced models are equipped with a variable-speed feed mechanism that allows operators to adjust the shot flow rate according to the cleaning requirements.
To ensure long-term durability, all components of the blast wheel assembly are made of high-wear-resistant materials. The impeller and blades are typically made of high-chromium cast iron or cemented carbide, which can withstand the high impact and abrasion caused by the steel shots. The control cage is made of thick steel plate with a wear-resistant coating, and the feed spout is lined with rubber or ceramic to prevent wear.
4.4 Shot Recovery and Recycling System
The shot recovery and recycling system is an essential part of the Steel Structure Roller Conveyor Shot Blasting Machine, as it allows for the efficient reuse of steel shots, reducing material costs and minimizing waste. This system consists of a screw conveyor, a bucket elevator, a separator, and a shot storage hopper.
After the steel shots are projected onto the workpiece surface, they fall to the bottom of the shot blasting chamber along with the dust and debris generated during the cleaning process. The screw conveyor, which is installed at the bottom of the chamber, collects these shots, dust, and debris and transports them to the bucket elevator.
The bucket elevator lifts the mixture of shots, dust, and debris to the top of the machine, where it is fed into the separator. The separator is designed to separate the reusable steel shots from the dust and debris. There are two main types of separators used in these machines: air separators and magnetic separators.
Air separators use a combination of gravity and air flow to separate the shots from the lighter dust and debris. As the mixture enters the separator, a stream of air blows the dust and small debris upward into a dust collection system, while the heavier steel shots fall downward into a collection chute.
Magnetic separators, on the other hand, use magnetic force to separate the steel shots from non-magnetic debris (such as rust and scale). The mixture passes over a magnetic drum, which attracts the steel shots and lifts them away from the debris. The debris falls into a waste chute, while the shots are carried by the drum to a collection chute.
Once separated, the reusable steel shots are transported to the shot storage hopper, where they are stored until they are fed back into the blast wheel assemblies for reuse. The shot storage hopper is equipped with a level sensor that monitors the shot level and triggers an alarm when the level is too low, ensuring that the machine never runs out of shots during operation.
4.5 Dust Collection System
As mentioned earlier in the “Features” section, the dust collection system is a critical component of the machine, responsible for capturing and filtering the dust and debris generated during the shot blasting process. In addition to the cyclone separator and bag filter mentioned previously, the dust collection system also includes a dust hood, ductwork, and a fan.
The dust hood is installed above the shot blasting chamber and the shot recovery system to capture the dust generated in these areas. The ductwork connects the dust hood, cyclone separator, bag filter, and fan, creating a closed system that ensures all dust is directed to the filtration components.
The fan provides the suction force needed to pull the dust through the ductwork and into the cyclone separator. The cyclone separator uses centrifugal force to separate the larger dust particles from the air. These larger particles fall to the bottom of the cyclone and are collected in a dust bin, which can be easily emptied.
The remaining air, which contains fine dust particles, then flows into the bag filter. The bag filter consists of a series of fabric bags that trap the fine dust particles as the air passes through them. The clean air is then discharged into the atmosphere through the fan.
To ensure the dust collection system operates efficiently, the bag filter is equipped with a cleaning mechanism, such as a pulse jet system. This system uses compressed air to blow the dust off the surface of the fabric bags at regular intervals, preventing clogging and maintaining the filter's performance.
4.6 Control System
The control system is the “brain” of the Steel Structure Roller Conveyor Shot Blasting Machine, responsible for coordinating the operation of all the machine's components. It consists of a programmable logic controller (PLC), a human-machine interface (HMI), sensors, and actuators.
The PLC is the core component of the control system, processing input signals from the sensors and sending output signals to the actuators to control the machine's operation. It is programmed to perform a range of functions, including starting and stopping the machine, adjusting the conveyor speed, controlling the shot flow rate, and monitoring the machine's performance.
The HMI is a touch-screen interface that allows operators to interact with the control system. Through the HMI, operators can set up the machine's parameters (such as conveyor speed, shot flow rate, and blast wheel speed), monitor the machine's operation in real-time (including the status of each component, the shot level, and the dust collection system performance), and access diagnostic information in case of a fault.
The sensors are used to collect data about the machine's operation and the workpieces being treated. Common sensors include position sensors (to detect the presence of workpieces), speed sensors (to monitor the conveyor and blast wheel speed), level sensors (to monitor the shot level in the hopper), and pressure sensors (to monitor the air pressure in the dust collection system).
The actuators are responsible for carrying out the commands from the PLC. They include motors (to drive the conveyor, blast wheels, and shot recovery system), valves (to control the shot flow and air pressure), and alarms (to alert operators of faults or abnormal conditions).
5. Basic Parameter
The basic parameters of the Steel Structure Roller Conveyor Shot Blasting Machine vary depending on the model and the specific requirements of the application. However, the following are the key parameters that are typically specified for these machines, along with typical ranges and explanations:
5.1 Workpiece Handling Capacity
The workpiece handling capacity refers to the maximum size, weight, and dimensions of the steel components that the machine can process. This parameter is critical for determining whether the machine is suitable for a particular application.
Maximum Workpiece Length: Typically ranges from 3 meters to 20 meters, depending on the machine's design. Longer machines are capable of handling large steel beams and trusses used in bridge and building construction.
Maximum Workpiece Width: Ranges from 0.5 meters to 3 meters. This parameter determines the maximum width of steel plates and profiles that can be processed.
Maximum Workpiece Height/Thickness: Ranges from 0.3 meters to 1.5 meters. This parameter is important for processing thick steel plates, columns, and other bulky components.
Maximum Workpiece Weight: Typically ranges from 1 ton to 50 tons. Heavy-duty machines are designed to handle large and heavy components such as boiler shells and pressure vessels.
For example, a machine designed for processing steel beams used in high-rise buildings may have a maximum workpiece length of 12 meters, width of 1.5 meters, height of 1 meter, and weight of 10 tons.
5.2 Shot Blasting Performance Parameters
These parameters determine the efficiency and effectiveness of the shot blasting process, including the speed and quality of surface cleaning.
Number of Blast Wheels: Ranges from 2 to 8, depending on the machine's size and the required cleaning intensity. Machines with more blast wheels are capable of faster and more thorough cleaning.
Blast Wheel Diameter: Typically ranges from 300 mm to 600 mm. Larger blast wheels can project more shots at higher speeds, increasing the cleaning efficiency.
Blast Wheel Speed: Ranges from 1500 rpm to 3000 rpm. Higher speeds result in higher shot projection velocities (up to 100 m/s), which are more effective at removing thick oxide layers and rust.
Shot Flow Rate: Ranges from 50 kg/min to 300 kg/min. This parameter refers to the amount of steel shots projected per minute. A higher shot flow rate is required for cleaning heavily contaminated workpieces.
Cleaning Efficiency: Expressed as the time required to achieve a specified surface cleanliness level (e.g., Sa 2.5 or Sa 3 according to ISO 8501-1). Typically, the machine can achieve Sa 2.5 cleanliness in 1-5 minutes per meter of workpiece length, depending on the workpiece's surface condition and the machine's parameters.
For instance, a machine with 4 blast wheels (diameter 500 mm, speed 2500 rpm) and a shot flow rate of 150 kg/min can achieve Sa 2.5 cleanliness on a moderately rusted steel beam (length 6 meters) in approximately 2 minutes.
5.3 Conveyor System Parameters
The conveyor system parameters determine the speed at which the workpieces are transported through the machine, which affects the residence time in the shot blasting chamber and the overall production efficiency.
Conveyor Speed: Adjustable, typically ranging from 0.5 m/min to 5 m/min. The speed can be adjusted based on the workpiece's surface condition and the required cleaning quality. A slower speed allows for longer residence time and more thorough cleaning, while a faster speed increases production throughput.
Roller Diameter: Ranges from 80 mm to 200 mm. Larger rollers are used for handling heavier workpieces to distribute the weight evenly and prevent deformation.
Roller Spacing: Adjustable, typically ranging from 200 mm to 800 mm. Smaller spacing is used for smaller workpieces to prevent them from falling between the rollers, while larger spacing is used for larger workpieces to reduce friction and improve transportation efficiency.
For example, when processing a lightly contaminated steel plate (length 4 meters), the conveyor speed can be set to 3 m/min, resulting in a residence time of approximately 1.3 minutes in the shot blasting chamber. For a heavily contaminated plate, the speed can be reduced to 1 m/min, increasing the residence time to 4 minutes.
5.4 Dust Collection System Parameters
These parameters ensure that the dust collection system operates efficiently and meets environmental regulations.
Air Volume: Ranges from 5000 m³/h to 30,000 m³/h. This parameter refers to the amount of air handled by the dust collection system per hour. A larger air volume is required for machines with higher shot flow rates and larger shot blasting chambers to ensure effective dust capture.
Filter Efficiency: Typically ≥ 99.9%. This parameter refers to the percentage of dust particles removed from the air. High filter efficiency ensures that the exhaust air meets national environmental standards (e.g., ≤ 50 mg/m³ for particulate matter).
Fan Power: Ranges from 11 kW to 75 kW. The fan power is determined by the air volume and the resistance of the ductwork and filters. A more powerful fan is required for larger air volumes and longer ductwork.
For example, a machine with a shot flow rate of 200 kg/min and a shot blasting chamber volume of 10 m³ may require a dust collection system with an air volume of 20,000 m³/h, a filter efficiency of 99.95%, and a fan power of 45 kW.
5.5 Power Consumption
Power consumption is an important parameter for evaluating the machine's operating costs and energy efficiency.
Total Installed Power: Ranges from 50 kW to 300 kW. This parameter includes the power required for the blast wheel motors, conveyor motor, shot recovery system motor, dust collection fan motor, and control system.
Specific Power Consumption: Typically ranges from 5 kWh/ton to 15 kWh/ton of workpiece processed. This parameter is calculated by dividing the total power consumption by the weight of the workpieces processed per hour.
For example, a machine with a total installed power of 150 kW and a workpiece throughput of 10 tons/hour has a specific power consumption of 15 kWh/ton. By optimizing the machine's parameters (e.g., reducing the blast wheel speed for lightly contaminated workpieces), the specific power consumption can be reduced to 8 kWh/ton.
5.6 Overall Dimensions and Weight
These parameters are important for determining the space required to install the machine and the transportation and installation requirements.
Machine Length: Ranges from 6 meters to 30 meters. Longer machines are required for handling longer workpieces and may include additional components such as a pre-heating section or post-treatment section.
Machine Width: Ranges from 2 meters to 6 meters. The width is determined by the maximum workpiece width and the number of blast wheels.
Machine Height: Ranges from 2.5 meters to 8 meters. The height is determined by the maximum workpiece height and the height of the shot recovery system and dust collection system.
Machine Weight: Ranges from 10 tons to 100 tons. Heavier machines are typically more durable and capable of handling heavier workpieces.
For example, a standard machine designed for processing steel beams (maximum length 10 meters) may have overall dimensions of 18 meters (length) × 3 meters (width) × 4 meters (height) and a weight of 40 tons. A heavy-duty machine designed for processing pressure vessels (maximum weight 50 tons) may have dimensions of 25 meters × 5 meters × 7 meters and a weight of 80 tons.
By understanding these basic parameters, manufacturers and users can select the most suitable Steel Structure Roller Conveyor Shot Blasting Machine for their specific applications, ensuring optimal performance, efficiency, and cost-effectiveness.
6. Maintenance and Care
Proper maintenance and care are essential to ensure the long-term stable operation, optimal performance, and extended service life of the Steel Structure Roller Conveyor Shot Blasting Machine. Neglecting maintenance can lead to increased downtime, reduced cleaning efficiency, and higher repair costs. Below are the key maintenance and care measures for the machine:
6.1 Daily Maintenance
Daily maintenance focuses on inspecting the machine's key components to identify and address minor issues before they escalate into major faults. Operators should perform the following tasks at the start and end of each workday:
Visual Inspection: Check the external condition of the machine, including the shot blasting chamber, roller conveyor, and dust collection system. Look for signs of damage, such as cracks in the chamber walls, bent rollers, or loose connections. Ensure that the sealing devices (rubber curtains, brush seals) at the chamber entrance and exit are intact and free from wear.
Shot Level Check: Monitor the shot level in the shot storage hopper using the level sensor or by visual inspection. If the level is below the recommended minimum, add new steel shots of the specified type and size to avoid interrupting the shot blasting process.
Dust Collection System Inspection: Check the dust bin of the cyclone separator and bag filter. Empty the dust bin if it is full to prevent clogging and ensure the dust collection system operates efficiently. Inspect the fabric bags of the bag filter for damage or excessive dust accumulation; replace any damaged bags immediately.
Lubrication Check: Verify the lubrication level of the roller conveyor bearings, blast wheel bearings, and other moving parts. Add the recommended lubricant (e.g., lithium-based grease) if the level is low. Ensure that the lubrication system is functioning properly and that there are no oil leaks.
Control System Test: Turn on the control system and check the HMI for error messages or abnormal indicators. Test the emergency stop button, safety interlocks, and alarms to ensure they are working correctly. Run a short test cycle with a small workpiece to verify that the conveyor speed, blast wheel speed, and shot flow rate are operating as set.
6.2 Weekly Maintenance
Weekly maintenance involves more in-depth inspections and maintenance tasks to ensure the machine's components are in good working condition:
Blast Wheel Assembly Inspection: Disassemble the blast wheel cover and inspect the impeller, blades, and control cage for wear. Measure the thickness of the blades and impeller; if they are worn beyond the specified limit (typically 30% of the original thickness), replace them. Check the tightness of the bolts connecting the blast wheel to the motor shaft; tighten any loose bolts.
Roller Conveyor Maintenance: Inspect the rollers for wear, deformation, or damage. Rotate the rollers manually to check for smooth operation; if a roller is stuck or makes abnormal noise, disassemble it and inspect the bearings. Replace worn or damaged bearings and clean the roller surface to remove any accumulated debris.
Shot Recovery System Check: Inspect the screw conveyor and bucket elevator for wear. Check the chain or belt tension of the bucket elevator; adjust if necessary. Ensure that the separator (air or magnetic) is functioning properly by testing its separation efficiency. Clean the separator's internal components to remove any accumulated dust or debris.
Electrical System Inspection: Check the electrical connections, including cables, terminals, and contactors, for looseness or corrosion. Inspect the motor windings for overheating by measuring the temperature with an infrared thermometer. Ensure that the electrical cabinet is clean and free from dust, which can cause short circuits.
6.3 Monthly Maintenance
Monthly maintenance focuses on comprehensive inspections and preventive maintenance to address potential issues that may not be detected during daily or weekly checks:
Shot Blasting Chamber Maintenance: Remove the wear-resistant liners (manganese steel plates, rubber liners) from the inner surface of the chamber and inspect them for wear. Replace any liners that are cracked, broken, or worn thin. Clean the chamber's internal surface to remove any accumulated shot fragments, dust, or debris.
Dust Collection System Overhaul: Remove all fabric bags from the bag filter and clean them with compressed air or water (if the bags are washable). Inspect the filter housing for corrosion or damage. Check the fan blades for wear and balance; if the blades are unbalanced, have them balanced by a professional to reduce vibration.
Control System Calibration: Calibrate the sensors (position sensors, speed sensors, level sensors) to ensure accurate data collection. Verify the accuracy of the HMI's parameter displays by comparing them with actual measurements (e.g., conveyor speed measured with a tachometer). Update the PLC program if necessary to address any operational issues or improve performance.
Lubrication System Maintenance: Clean the lubrication lines and filters to remove any contaminants. Replace the lubricant in the gearboxes of the roller conveyor and shot recovery system with the recommended type and grade. Inspect the lubrication pumps for proper operation and adjust the oil supply rate if needed.
6.4 Annual Maintenance
Annual maintenance is a comprehensive overhaul of the entire machine to ensure it operates at peak performance and meets safety standards:
Complete Disassembly and Inspection: Disassemble the key components of the machine, including the blast wheel assemblies, roller conveyor, shot recovery system, and dust collection system. Inspect each component for wear, fatigue, or damage. Replace any components that are 接近 the end of their service life, even if they are still functioning.
Structural Integrity Check: Inspect the machine's frame, shot blasting chamber, and other structural components for cracks, deformation, or corrosion. Weld any cracks and repair any deformed parts. Apply anti-corrosion paint to the external surface of the machine to prevent rust.
Motor and Gearbox Maintenance: Send the motors (blast wheel motors, conveyor motor, fan motor) and gearboxes to a professional repair shop for overhaul. This includes cleaning the motor windings, replacing worn bearings, and checking the gear teeth for wear. Test the motors and gearboxes after overhaul to ensure they meet the original performance specifications.
Safety System Verification: Conduct a comprehensive safety audit of the machine, including testing the emergency stop system, safety guards, and interlocks. Ensure that all safety labels and warning signs are clearly visible and legible. Update the safety operating procedures if necessary to reflect any changes in the machine's configuration or operation.
By following a regular maintenance schedule, operators can minimize downtime, reduce repair costs, and ensure the Steel Structure Roller Conveyor Shot Blasting Machine operates safely and efficiently for many years.
7. Safety Operation Specifications
The Steel Structure Roller Conveyor Shot Blasting Machine involves high-speed moving parts, high-pressure air, and the projection of steel shots, which pose potential safety hazards to operators if not operated properly. Therefore, strict adherence to safety operation specifications is essential to prevent accidents and ensure the safety of personnel and equipment. Below are the key safety operation requirements:
7.1 Pre-Operation Safety Checks
Before starting the machine, operators must perform the following safety checks to ensure the machine is in a safe operating condition:
Personal Protective Equipment (PPE): Wear the required PPE, including safety glasses, earplugs or earmuffs (to protect against noise), dust masks or respirators (to prevent inhalation of dust), safety gloves, and steel-toed boots. Ensure that the PPE is in good condition and fits properly.
Machine Inspection: As part of the daily maintenance, check the machine for any safety hazards, such as loose parts, damaged safety guards, or leaking lubricants. Ensure that the emergency stop button is easily accessible and functioning correctly.
Workpiece Preparation: Inspect the workpiece to be processed for any loose parts, sharp edges, or foreign objects (e.g., bolts, nuts) that could be dislodged during shot blasting and cause injury. Secure the workpiece firmly on the roller conveyor to prevent it from shifting or falling during transportation.
Work Area Safety: Clear the work area around the machine of any obstacles, debris, or other personnel. Ensure that the machine's access doors and inspection hatches are closed and locked to prevent dust leakage and unauthorized access.
7.2 During-Operation Safety Rules
During the operation of the machine, operators must follow these safety rules to avoid accidents:
No Unauthorized Access: Only trained and authorized operators are allowed to operate the machine. Keep other personnel at least 2 meters away from the machine during operation to prevent injury from flying shot fragments or dust.
Monitor Machine Operation: Continuously monitor the machine's operation through the HMI and by visual inspection. If any abnormal conditions are detected, such as excessive vibration, unusual noise, or a drop in cleaning efficiency, stop the machine immediately and investigate the cause.
Do Not Overload the Machine: Do not process workpieces that exceed the machine's maximum handling capacity (size, weight). Overloading can cause the roller conveyor to jam, the blast wheels to wear prematurely, or the machine to malfunction, leading to accidents.
Avoid Reaching into the Chamber: Never reach into the shot blasting chamber while the machine is in operation, even if the conveyor is stopped. The blast wheels may still be rotating, and there is a risk of being hit by flying shots. If it is necessary to access the chamber, turn off the machine and lock the main power switch.
Handle Shots Safely: When adding new shots to the shot storage hopper, use a dedicated tool (e.g., a shovel with a long handle) to avoid direct contact with the shots. Wear gloves to prevent cuts from sharp shot fragments.
7.3 Post-Operation Safety Procedures
After completing the shot blasting process, operators must follow these safety procedures to ensure the machine is safely shut down and the work area is safe:
Shut Down the Machine in Sequence: Follow the correct shutdown sequence as specified in the machine's operation manual. Typically, this involves stopping the blast wheels first, then the roller conveyor, and finally the dust collection system. Do not turn off the main power switch until all components have come to a complete stop.
Clean the Work Area: Clean the work area around the machine, including the floor, to remove any spilled shots, dust, or debris. Collect the reusable shots and return them to the shot storage hopper. Dispose of the waste dust and debris in accordance with environmental regulations.
Inspect the Machine: Perform a post-operation inspection of the machine to check for any damage or wear that may have occurred during operation. Record any issues in the maintenance log and schedule repairs if necessary.
Store PPE Properly: Clean and store the PPE in a designated area to ensure it is ready for use in the next shift. Inspect the PPE for damage and replace any worn or damaged items.
7.4 Emergency Handling
In the event of an emergency (e.g., fire, electrical shock, or injury to personnel), operators must take the following immediate actions:
Stop the Machine: Press the emergency stop button to shut down the machine immediately. Turn off the main power switch and disconnect the power supply to prevent further damage or danger.
Attend to Injured Personnel: If a person is injured, provide first aid immediately and call for emergency medical assistance. Do not move the injured person unless it is necessary to avoid further harm.
Extinguish Fires: If a fire breaks out, use the appropriate fire extinguisher (e.g., dry powder extinguisher for electrical fires) to extinguish the fire. Evacuate the area if the fire cannot be controlled and call the fire department.
Report the Incident: After the emergency is under control, report the incident to the supervisor and document the details (time, location, cause, and actions taken) in the safety incident log. Conduct an investigation to identify the root cause and take preventive measures to avoid similar incidents in the future.
By strictly following these safety operation specifications, operators can minimize the risk of accidents and ensure a safe working environment for themselves and others.
8. Selection Guide
Selecting the right Steel Structure Roller Conveyor Shot Blasting Machine is crucial to meet the specific requirements of the application, ensure optimal performance, and avoid unnecessary costs. The selection process involves considering a range of factors, including the characteristics of the workpieces, production requirements, environmental conditions, and budget. Below is a step-by-step selection guide to help users choose the most suitable machine:
8.1 Define Workpiece Characteristics
The first step in selecting the machine is to clearly define the characteristics of the steel workpieces to be processed, as these directly affect the machine's design and performance requirements:
Dimensions and Weight: Determine the maximum length, width, height/thickness, and weight of the workpieces. This information is used to select the appropriate size of the roller conveyor, shot blasting chamber, and machine frame to ensure the workpieces can be transported and processed safely.
Surface Condition: Assess the initial surface condition of the workpieces, including the type and thickness of contaminants (rust, scale, oil, paint) and the desired surface cleanliness level (e.g., Sa 2.0, Sa 2.5, Sa 3 according to ISO 8501-1). Workpieces with thick or stubborn contaminants require a machine with higher shot blasting intensity (more blast wheels, higher shot flow rate).
Material and Hardness: Consider the material and hardness of the workpieces. For high-hardness steel (e.g., alloy steel), a machine with blast wheels made of high-wear-resistant materials (cemented carbide) is recommended to avoid excessive wear of the blast wheel components.
Shape and Complexity: Evaluate the shape and complexity of the workpieces. Simple shapes (flat plates, straight beams) can be processed with a standard machine, while complex shapes (curved beams, irregular profiles) may require a machine with adjustable blast wheel angles or additional blast wheels to ensure uniform cleaning.
8.2 Determine Production Requirements
Production requirements, such as throughput, production schedule, and flexibility, are important factors in selecting the machine:
Throughput: Calculate the required throughput (weight or number of workpieces processed per hour) based on the production plan. This determines the machine's conveyor speed, shot flow rate, and number of blast wheels. A higher throughput requires a machine with a faster conveyor speed and more powerful shot blasting system.
Production Schedule: Consider whether the production is continuous or intermittent. For continuous production, a machine with a high degree of automation, reliable components, and easy maintenance is preferred to minimize downtime. For intermittent production, a machine with a smaller footprint and lower initial cost may be more suitable.
Flexibility: Determine if the machine needs to handle multiple types of workpieces with different dimensions and surface conditions. A flexible machine with adjustable parameters (conveyor speed, shot flow rate, blast wheel speed) and interchangeable components (wear-resistant liners, blast wheel blades) can adapt to changing production needs.
8.3 Consider Environmental and Safety Requirements
Environmental and safety regulations vary by region and industry, and the selected machine must comply with these requirements:
Environmental Regulations: Check the local environmental regulations regarding air emissions (dust, noise) and waste disposal. Select a machine with a high-efficiency dust collection system (filter efficiency ≥ 99.9%) to ensure the exhaust air meets the emission standards. If noise is a concern, choose a machine with sound insulation measures (e.g., soundproofing panels around the shot blasting chamber).
Safety Standards: Ensure the machine complies with international safety standards (e.g., OSHA in the United States, CE in the European Union). The machine should be equipped with safety features such as emergency stop buttons, safety guards, interlocks, and warning signs to protect operators from injury.
8.4 Evaluate Machine Performance and Reliability
The performance and reliability of the machine are critical to ensuring long-term operational efficiency and reducing maintenance costs:
Cleaning Efficiency: Review the machine's cleaning efficiency data, including the time required to achieve the desired surface cleanliness level for different types of workpieces. Choose a machine that can meet the cleaning requirements within the required time frame.
Component Quality: Inspect the quality of the machine's key components, such as blast wheels, rollers, motors, and control systems. Components made by well-known brands with a proven track record of reliability are preferred, as they are less likely to fail and require fewer repairs.
Maintenance Requirements: Evaluate the machine's maintenance requirements, including the frequency of maintenance, the availability of spare parts, and the ease of maintenance. A machine with simple maintenance procedures, easy access to components, and a local supply of spare parts can reduce downtime and maintenance costs.
8.5 Compare Costs and After-Sales Service
Cost is an important consideration, but it should not be the sole factor. Users should compare the total cost of ownership (initial purchase cost, operating cost, maintenance cost) and the quality of after-sales service:
Initial Purchase Cost: Obtain quotes from multiple suppliers and compare the initial purchase cost of different machines. However, do not select a machine based solely on the lowest price, as it may have lower quality components and higher long-term costs.
Operating Cost: Calculate the operating cost, including energy consumption, shot consumption, and labor cost. A machine with high energy efficiency (low specific power consumption) and a shot recovery system that minimizes shot waste can reduce operating costs.
Maintenance Cost: Estimate the maintenance cost, including the cost of spare parts, lubricants, and labor. A machine with durable components and a simple maintenance design will have lower maintenance costs over its service life.
After-Sales Service: Evaluate the supplier's after-sales service, including installation, training, technical support, and spare parts supply. Choose a supplier with a local service team that can provide timely support and has a sufficient inventory of spare parts to minimize downtime.
By following this selection guide and carefully considering all relevant factors, users can select a Steel Structure Roller Conveyor Shot Blasting Machine that meets their specific needs, ensures optimal performance, and provides long-term value for money.
