Heavy-Duty H Beam Shot Peening Machine Model
1. Brief Profile
The Heavy-Duty H Beam Shot Peening Machine Model is a specialized industrial equipment engineered to enhance the fatigue resistance and structural integrity of large, thick-walled H-shaped steel components. Unlike standard shot blasting machines that focus on surface cleaning, this heavy-duty model uses high-velocity, high-density shot peening to introduce compressive residual stress into the H beam’s surface layer—critical for mitigating crack initiation and propagation in heavy-load applications.
Designed for H beams with extreme dimensions (flange widths up to 800mm, web heights up to 1200mm, and weights up to 10 tons), this model addresses the unique challenges of heavy-duty steel processing. Heavy H beams are widely used in stress-intensive scenarios (e.g., bridge piers, offshore platforms, heavy machinery frames), where even minor surface defects can lead to catastrophic failure under long-term loads. The machine’s peening process targets not only the external surfaces of flanges and webs but also the high-stress inner corners of flanges—areas prone to stress concentration.
Key to its heavy-duty performance is the robust structural design: the machine frame is made of high-strength Q355B steel with reinforced crossbeams to withstand the vibration and impact of processing large H beams. The peening system uses industrial-grade cast steel shots (2.0–3.0mm) propelled by high-power blast wheels (45–75kW each), delivering a peening intensity of 0.2–0.6mmA (Almen intensity) to meet the strict standards of industries like offshore engineering and heavy machinery.
Intelligent control is another core feature. The machine is equipped with a PLC system with preprogrammed parameters for common heavy H beam grades (e.g., Q355, Q460, S355JR) and a touch-screen HMI for real-time monitoring of peening intensity, shot flow rate, and conveyor speed. This ensures consistent results across batches, even for operators with limited expertise.
In summary, this heavy-duty model is not just a surface treatment tool but a reliability-enhancing solution for heavy H beams. By combining high-intensity peening, robust construction, and intelligent control, it meets the demanding performance requirements of industries where structural safety and long service life are non-negotiable.
2. Application
The Heavy-Duty H Beam Shot Peening Machine Model is tailored to industries that rely on large, high-stress H beams, where fatigue resistance is critical to preventing operational failures. Its ability to process ultra-large H beams and deliver consistent compressive stress makes it indispensable in heavy-industry sectors. Below are its key application areas:
2.1 Offshore and Marine Engineering
Offshore platforms (oil rigs, wind turbine foundations) use heavy H beams (flange widths 600–800mm, web heights 1000–1200mm) that endure harsh marine environments—saltwater corrosion, wave impact, and cyclic loads. The machine’s shot peening process introduces a 0.1–0.3mm deep compressive stress layer on the H beam’s surface, significantly reducing the risk of stress corrosion cracking. For example, in wind turbine foundation H beams, peening the flange inner corners (a high-stress area) extends the component’s fatigue life by 2–3 times compared to unpeened beams, ensuring the foundation withstands 20+ years of wind and wave loads.
2.2 Heavy Machinery Manufacturing
Machinery like mining excavators, port cranes, and steel mill rolling stands use heavy H beams in their frames and booms, which bear static loads of 50+ tons and dynamic impacts during operation. The machine processes H beams with web thicknesses up to 50mm, delivering a peening intensity of 0.4–0.6mmA to strengthen the surface. For a mining excavator’s boom H beam (weight 8 tons, flange width 700mm), peening enhances the beam’s resistance to bending fatigue, reducing maintenance downtime by 40% and extending the boom’s service life from 5 to 8 years.
2.3 Bridge and Infrastructure Construction
Long-span bridges (highway, railway) and large-scale infrastructure (airport terminals, stadiums) use heavy H beams in load-bearing structures (piers, main girders). These beams face cyclic loads from traffic, temperature changes, and environmental stress. The machine peens H beams with lengths up to 30m, ensuring uniform compressive stress across the entire beam. For a highway bridge’s main girder H beam (flange width 800mm, web height 1100mm), peening the flange edges and web connections reduces the risk of fatigue cracking, aligning with bridge design standards that require 100+ years of service life.
2.4 Power Generation Industry
Thermal power plants and nuclear power facilities use heavy H beams in boiler supports, turbine foundations, and structural frames. These beams operate in high-temperature (up to 400°C) and high-pressure environments, where fatigue failure can lead to catastrophic accidents. The machine’s high-temperature-resistant peening system (using heat-stable steel shots) processes H beams for power plant applications, delivering a compressive stress layer that retains its effectiveness under high temperatures. For a thermal power plant’s boiler support H beam (weight 10 tons), peening ensures the beam withstands thermal cycling and mechanical loads for 30+ years.
3. Features
The Heavy-Duty H Beam Shot Peening Machine Model is distinguished by features optimized for processing large, high-stress H beams—focused on high peening intensity, structural robustness, and uniform stress distribution. These features ensure the machine meets the strict performance standards of heavy industries while maintaining operational efficiency and safety:
3.1 High-Intensity Peening System for Heavy H Beams
To deliver the required compressive stress to thick-walled H beams, the machine uses a powerful, multi-wheel peening system:
High-Power Blast Wheels: Equipped with 8–12 blast wheels (diameter 500–700mm) driven by 45–75kW motors. Each wheel operates at 2000–3000 rpm, propelling 2.0–3.0mm cast steel shots at velocities of 90–120 m/s—generating a peening intensity of 0.2–0.6mmA (Almen intensity). This is 50–100% higher than standard shot peening machines, ensuring deep compressive stress penetration (0.1–0.3mm) into thick H beam surfaces (web/flange thickness up to 50mm).
Dual-Angle Peening Design: Horizontal blast wheels (4–6) target the top and bottom surfaces of H beam flanges, while vertical blast wheels (4–6) are angled at 25°–45° to reach the inner corners of flanges—a high-stress area often missed by standard machines. The vertical wheels are mounted on hydraulic adjustable brackets, allowing operators to fine-tune the angle based on flange width (400–800mm), ensuring uniform peening of all critical surfaces.
Variable Shot Flow Control: A dual vibratory feeder system delivers shots at a rate of 300–600 kg/min, adjustable via the PLC. For thick H beams (web thickness ≥30mm), the flow rate is increased to 500–600 kg/min to maintain peening intensity; for thinner sections (web thickness 10–20mm), it is reduced to 300–400 kg/min to avoid surface over-peening.
3.2 Robust Structural Design for Heavy Loads
The machine’s frame and components are engineered to handle the weight and vibration of processing 10-ton H beams:
High-Strength Frame: Constructed from Q355B steel with reinforced crossbeams and floor anchors. The frame’s load-bearing capacity is 15 tons (50% higher than the maximum H beam weight), preventing deformation under long-term use. The base is mounted on shock-absorbing rubber pads (50mm thick) to reduce vibration transmission to the workshop floor—critical for protecting nearby equipment and ensuring operator comfort.
Heavy-Duty Conveyor System: The roller conveyor uses 150–200mm diameter rollers made from 42CrMo alloy steel (hardness HRC 55–60) to support 10-ton H beams without bending. Roller spacing is 400–600mm, adjustable via a hydraulic system, to evenly distribute the beam’s weight and prevent sagging during transport. The conveyor drive uses a 22–37kW variable-frequency motor with a torque booster, ensuring smooth movement even for unevenly weighted H beams.
Wear-Resistant Chamber Lining: The peening chamber (length 6–10m, width 2–4m, height 3–5m) is lined with 20mm thick Mn13 wear-resistant steel plates—capable of withstanding 5000+ hours of shot impact before replacement. The chamber’s inner walls are sloped at 30° to direct shots and debris toward the recovery system, minimizing shot loss and reducing maintenance.
3.3 Intelligent Peening Control and Quality Assurance
To ensure consistent results and compliance with industry standards, the machine integrates advanced control and monitoring features:
Almen Intensity Monitoring: A built-in Almen gauge system automatically measures peening intensity (0.2–0.6mmA) at 10-second intervals during operation. If intensity deviates by ±0.05mmA (e.g., due to shot wear), the PLC adjusts the blast wheel speed or shot flow rate to correct it—ensuring uniform stress across all H beams.
H Beam Grade Presets: The PLC stores 20+ preprogrammed parameters for common heavy H beam grades (Q355, Q460, S355JR, A572). Operators select the beam grade, and the system automatically sets peening intensity, shot size, and conveyor speed. For example, selecting Q460 (high-strength steel) triggers a higher intensity (0.5–0.6mmA) and slower conveyor speed (0.3–0.5 m/min) to ensure sufficient stress penetration.
Vision Inspection System: A camera array at the chamber exit captures high-resolution images of the H beam’s surface, analyzing shot coverage and surface roughness (Ra 5–15μm). If coverage is below 98% (a requirement for offshore and nuclear applications), the system alerts operators and diverts the beam to a re-peening station—preventing non-compliant components from entering the next process.
3.4 Efficient Shot Recovery and Environmental Protection
The machine’s closed-loop shot management and dust collection systems minimize waste and meet strict environmental standards:
Triple-Stage Shot Recovery: Shots and debris are first collected by screw conveyors (diameter 300–400mm) and transported to a magnetic separator, which removes 98% of steel shots from non-magnetic debris (rust, scale). Next, an air classifier separates worn shots (≤1.8mm) from usable ones (2.0–3.0mm), ensuring only high-quality shots are recycled. Finally, a shot polishing unit removes surface contaminants from recycled shots, maintaining consistent peening performance.
High-Efficiency Dust Collection: A dual-filter system (cyclone + HEPA) captures 99.99% of peening dust (particle size ≥0.1μm). The cyclone removes large dust particles (≥10μm), while the HEPA filter traps fine particles—meeting the EU’s EN 15038 (emission limit ≤10 mg/m³) and the US EPA’s MACT standards for heavy industry. The dust collection fan uses a 45–75kW motor with variable speed, adjusting airflow (20,000–40,000 m³/h) based on peening intensity to reduce energy consumption.
4. Main parts
The Heavy-Duty H Beam Shot Peening Machine Model consists of interconnected, heavy-duty components—each designed to handle the stress of processing large H beams and deliver consistent peening results. These parts are engineered for durability, efficiency, and ease of maintenance, ensuring long-term reliable operation in heavy-industry environments:
4.1 Heavy-Duty Conveyor and Alignment Module
This module transports and positions heavy H beams (up to 10 tons) for precise peening:
Load-Bearing Rollers: 150–200mm diameter rollers made from 42CrMo alloy steel, heat-treated to HRC 55–60 for wear resistance. Each roller has a load capacity of 1.5 tons, with 8–12 rollers supporting a single H beam to distribute weight evenly. The rollers are sealed with double-lip bearings to prevent dust and shot debris from entering, extending their service life to 8000+ hours.
Hydraulic Alignment Guides: Two 3m tall steel guides (thickness 20mm) mounted on either side of the conveyor, adjustable via hydraulic cylinders (pressure 10–15MPa) to match H beam flange widths (400–800mm). The guides have rubber-lined surfaces to prevent scratches on the H beam and include laser position sensors that send real-time data to the PLC—ensuring the beam is centered in the peening chamber to avoid uneven peening.
Conveyor Drive System: A 22–37kW variable-frequency motor connected to a planetary gear reducer (reduction ratio 1:50) provides smooth, high-torque power to the rollers. The drive system includes a torque limiter that shuts down the conveyor if the H beam jams—protecting the motor and rollers from damage. Conveyor speed is adjustable from 0.2–1 m/min, with a precision of ±0.05 m/min to control peening duration.
4.2 High-Intensity Peening Chamber
The chamber is the core of the machine, where the shot peening process occurs:
Chamber Structure: A steel enclosure (length 6–10m, width 2–4m, height 3–5m) welded from 16mm thick Q355B steel plates. The chamber is reinforced with 100×100mm steel angle irons spaced 500mm apart to withstand internal pressure and shot impact. The entrance and exit are equipped with double-layer rubber curtains (50mm thick) to prevent shot leakage and dust escape—each curtain is replaceable and designed to last 1000+ hours of use.
Blast Wheel Assemblies: 8–12 blast wheels (diameter 500–700mm) mounted in horizontal and vertical positions. Each wheel consists of a high-chromium cast iron impeller (Cr26) and blades (Cr20), which resist wear from 2.0–3.0mm steel shots. The wheels are dynamically balanced to reduce vibration, with a runout tolerance of ≤0.1mm. Each blast wheel is connected to a 45–75kW motor via a flexible coupling, allowing for easy maintenance and replacement.
Shot Distribution Nozzles: Each blast wheel is fitted with a custom-designed nozzle that shapes the shot stream into a 30°–45° fan pattern. The nozzles are made from cemented carbide (WC-Co) for wear resistance and are adjustable to control the shot coverage area—critical for ensuring the entire H beam surface (including flange inner corners) is peened.
4.3 Shot Recovery and Recycling Module
This module ensures efficient reuse of steel shots and minimizes waste:
Screw Conveyors: 2–4 horizontal screw conveyors (length 6–10m, diameter 300–400mm) installed at the bottom of the peening chamber. The screws are made from Mn13 wear-resistant steel, with a pitch of 200mm to transport shots and debris at a rate of 500–800 kg/min. The conveyors are driven by 7.5–15kW motors and include a self-cleaning design to prevent shot buildup.
Magnetic Separator: A rotating magnetic drum (diameter 500–600mm, length 1.5–2m) with a neodymium-iron-boron (NdFeB) magnet core (magnetic strength 12,000 gauss). The drum rotates at 20–30 rpm, attracting steel shots and separating them from non-magnetic debris (rust, scale). The separated shots are scraped off by a non-magnetic stainless steel scraper and sent to the air classifier, while debris falls into a sealed waste bin (volume 2–4 m³) for disposal.
Air Classifier: A vertical air column (height 3–4m, diameter 500mm) that uses controlled airflow (15–25 m/s) to separate worn shots (≤1.8mm) from usable ones (2.0–3.0mm). Worn shots are directed to a waste chute, while usable shots are sent to a shot polishing unit. The classifier includes a particle size sensor that monitors shot size distribution, alerting operators when the proportion of worn shots exceeds 10%.
Shot Polishing Unit: A cylindrical drum (length 2m, diameter 1m) filled with abrasive stones that remove surface rust and contaminants from recycled shots. The unit operates at 50–60 rpm, with a processing capacity of 300–500 kg/h, ensuring recycled shots have the same surface quality as new ones.
4.4 Dust Collection and Control Module
This module maintains a clean working environment and complies with environmental regulations:
Cyclone Separator: A large cyclone (diameter 1–1.5m, height 3–4m) that uses centrifugal force to remove 90% of dust particles (≥10μm) from the air. The cyclone’s inlet is designed to minimize pressure loss, and the bottom is equipped with a pneumatic discharge valve that empties collected dust into a sealed bin (volume 1–2 m³) at 30-minute intervals—reducing manual intervention. The cyclone is made from 12mm thick Q235 steel with an anti-corrosion coating to withstand the abrasive nature of peening dust.
HEPA Filter Unit: A bank of 15–20 HEPA filters (each with a filtration area of 10 m²) that captures 99.99% of fine dust particles (≥0.1μm). The filters are made from PTFE-coated fiberglass, which is resistant to moisture and chemical corrosion—critical for offshore or marine engineering facilities with high humidity. The unit includes a pulse-jet cleaning system: compressed air (0.6–0.8MPa) is periodically blown into the filters to dislodge accumulated dust, with the cleaning cycle adjustable from 5–15 minutes based on dust load.
Exhaust Fan and Ductwork: A 45–75kW centrifugal fan that generates airflow of 20,000–40,000 m³/h, pulling dust-laden air from the peening chamber through the cyclone and HEPA filter. The fan is mounted on a vibration-isolated base to reduce noise (≤85 dB) and extends its service life. The ductwork is made from 3mm thick galvanized steel, with a diameter of 500–800mm to minimize pressure loss. It is designed with smooth bends to avoid dust buildup and includes inspection hatches for easy cleaning.
4.5 Control and Monitoring Module
This module serves as the “brain” of the machine, ensuring precise control of the peening process and real-time quality monitoring:
PLC Control System: A Siemens S7-1500 or Allen-Bradley ControlLogix PLC that processes input from sensors (Almen gauge, vision camera, position sensor) and sends commands to the machine’s components. It stores 20+ preprogrammed parameters for heavy H beam grades and allows operators to create custom profiles for unique beam sizes. The PLC also includes a fault diagnosis function—if a component (e.g., blast wheel motor) malfunctions, it displays a troubleshooting guide on the HMI to reduce downtime.
Touch-Screen HMI: A 15-inch industrial touch screen (resistant to dust, oil, and water) that provides real-time visibility of key parameters: peening intensity (0.2–0.6mmA), shot flow rate (300–600 kg/min), conveyor speed (0.2–1 m/min), and filter status. Operators can adjust parameters with a single tap, and the HMI logs all process data (date, time, beam ID, peening results) for 12 months—enabling traceability for industries like nuclear power or aerospace with strict quality records.
Safety Interlocks: The module includes multiple safety features to protect operators and equipment: emergency stop buttons (mounted at 3–5 positions around the machine), door interlocks (the machine shuts down if the peening chamber door is opened), and overload protection for the conveyor and blast wheel motors. These features comply with international safety standards (OSHA 1910, CE EN ISO 12100).
5. Basic Parameter
The basic parameters of the Heavy-Duty H Beam Shot Peening Machine Model are tailored to the extreme dimensions and performance requirements of heavy H beams, ensuring the machine meets the needs of stress-intensive industries (offshore, heavy machinery, bridge construction). These parameters balance high peening intensity, structural robustness, and operational efficiency, with flexibility to adapt to diverse H beam specifications:
5.1 H Beam Handling Capacity
This parameter defines the machine’s ability to process large, heavy H beams—critical for matching the production needs of heavy-industry facilities:
Maximum H Beam Weight: 5–10 tons. Standard heavy-duty models handle 5–8 tons (flange width ≤600mm, web height ≤1000mm), while ultra-heavy models process 8–10 tons (flange width 600–800mm, web height 1000–1200mm). The machine’s conveyor and frame are reinforced to support this weight, with a safety margin of 50% (e.g., 15-ton load capacity for 10-ton beams) to prevent structural damage.
H Beam Cross-Section Range:
Flange Width: 400–800mm (accommodated by adjustable vertical blast wheels and alignment guides). For flanges wider than 600mm, the machine adds 1–2 extra vertical blast wheels to ensure full coverage of inner corners.
Web Height: 600–1200mm (matched to the peening chamber’s internal height of 3–5m). The chamber’s height is adjustable via hydraulic lifts for web heights exceeding 1000mm.
Web/Flange Thickness: 10–50mm. The machine’s peening intensity (0.2–0.6mmA) is adjustable to ensure deep stress penetration (0.1–0.3mm) for thick sections (≥30mm) while avoiding over-peening for thin sections (10–20mm).
Maximum H Beam Length: 20–30m. The machine’s infeed and outfeed conveyors are extended to 8–12m each to support long beams, preventing sagging during transport. For beams longer than 30m, the machine can be customized with modular conveyor extensions.
5.2 Peening Performance Parameters
These parameters determine the machine’s ability to deliver the required compressive stress and surface quality for heavy H beams:
Number of Blast Wheels: 8–12 wheels (4–6 horizontal, 4–6 vertical). Ultra-heavy models (10-ton capacity) use 10–12 wheels to maintain intensity for large beams, while standard heavy-duty models use 8 wheels.
Blast Wheel Specifications:
Diameter: 500–700mm (larger wheels for higher shot velocity).
Motor Power: 45–75kW per wheel (vertical wheels: 45–55kW; horizontal wheels: 60–75kW for larger flange surfaces).
Rotational Speed: 2000–3000 rpm (adjustable via VFD), generating shot velocities of 90–120 m/s.
Shot Type and Size:
Material: Cast steel shots (hardness HRC 45–50) or stainless steel shots (for corrosion-sensitive applications like offshore).
Size: 2.0–3.0mm (larger than standard shot peening machines to ensure deep stress penetration).
Shot Flow Rate: 300–600 kg/min (adjustable via dual vibratory feeders). Ultra-heavy models use 500–600 kg/min for 8–10 ton beams, while standard models use 300–400 kg/min.
Peening Intensity: 0.2–0.6mmA (Almen intensity, measured via built-in Almen gauge). For high-stress applications (offshore platforms), intensity is set to 0.4–0.6mmA; for general heavy machinery, it is set to 0.2–0.4mmA.
Surface Coverage: ≥98% (ensured by the vision inspection system), meeting the requirements of ISO 18795 (shot peening for automotive and industrial components) and AWS D1.1 (bridge welding standards).
5.3 Conveyor and Throughput Parameters
These parameters impact the machine’s production efficiency and ability to handle continuous heavy-industry workflows:
Conveyor Speed: 0.2–1 m/min (adjustable via VFD). Slower speeds (0.2–0.5 m/min) are used for high-intensity peening (0.4–0.6mmA), while faster speeds (0.6–1 m/min) are for lower intensity (0.2–0.4mmA). Speed precision is ±0.05 m/min to ensure consistent peening duration.
Throughput: 3–8 H beams per hour (depending on beam length and peening intensity). A standard heavy-duty model processing 20m-long beams at 0.5 m/min handles 3–4 beams per hour, while an ultra-heavy model processing 25m beams at 0.3 m/min handles 2–3 beams per hour.
Conveyor Roller Specifications:
Diameter: 150–200mm (42CrMo alloy steel, HRC 55–60).
Spacing: 400–600mm (adjustable via hydraulic system to match beam weight).
Load Capacity per Roller: 1.5 tons (8–12 rollers support a 10-ton beam).
5.4 Power Consumption and Environmental Parameters
These parameters reflect the machine’s operational costs and compliance with global environmental standards:
Total Installed Power: 400–800kW. Ultra-heavy models (12 blast wheels, 75kW fan) use 600–800kW, while standard models use 400–500kW. The machine includes energy-saving features: blast wheels and fan automatically reduce speed during idle periods, cutting power consumption by 20–30%.
Dust Collection Performance:
Air Volume: 20,000–40,000 m³/h.
Filtration Efficiency: ≥99.99% for particles ≥0.1μm.
Emission Level: ≤10 mg/m³ (meets EU EN 15038 and US EPA MACT standards).
Noise Level: ≤85 dB (measured at 1m from the machine), compliant with OSHA noise regulations (≤90 dB for 8-hour exposure).
5.5 Overall Dimensions and Installation Requirements
These parameters guide the machine’s layout and installation in heavy-industry facilities:
Overall Dimensions:
Length: 35–50m (infeed: 8–12m + chamber: 6–10m + recovery: 10–15m + outfeed: 8–12m).
Width: 4–6m (chamber width: 2–4m + dust collection system: 2–3m).
Height: 5–8m (chamber height: 3–5m + shot hopper/recovery: 2–3m).
Installation Requirements:
Foundation: Concrete foundation with load-bearing capacity of 20–30 kN/m² (to support the machine’s weight of 50–100 tons).
Space: Clear area of 50×10m around the machine for maintenance and beam handling.
Power Supply: 380V/50Hz (3-phase) or 480V/60Hz (customizable for regional standards), with a dedicated transformer to handle high power consumption.
These basic parameters ensure the Heavy-Duty H Beam Shot Peening Machine Model can be tailored to the unique needs of heavy-industry applications—from offshore platforms to long-span bridges. By balancing high peening intensity, structural robustness, and intelligent control, the machine delivers consistent, reliable performance that enhances the fatigue life and safety of heavy H beams.
