SS10自动喷砂机的英文说明
1. general introduction of ss-10 wet blast machine
1.1 application
driven by media pumpandcompressed air, this machine is a new type of equipment specially designed forwet blast process utilized in finish.
the machine can clear castings andforgings, weldments, heat-treated parts, punched and machined workpieces andcan knock off the rough surface, oxide crust, remaining salt, burs, and etc. itcan be applied to do pre-treatment for coating and plating, high precision andhigh smoothness finish process on complicated-shaped components that othermethods cannot accomplish. it’s also very good at renovating used machinedparts.
1.2 features
1). dust pollution is effectivelyunder control during process.
2). no need of any extra ventilatorａnd dust remover, this machine can be directly installed on a product line soas to save working area and facilitate parts flowing.
3). with the variety of flexibleoperating methods and technological parameters, this machine is fit forrequirements of finish processing for parts made of different materials or invarious precisions.
4). the blasting process canimprove machined parts surface quality and reinforce parts skin so as toincrease wear-resistance and fatigue strength.
5). media consumption is limited.
6). major components of the machineare long-lived and are easy to be maintained
7). operator works in a low laborintensity with a high production efficiency.
1.3 buildup
the machinecomposed by main unit, outer guide track, media collector and separator asshown in ss-10 wet blast machine view, can be used in basic operation of thewet blast process and accessorial operations later.
1.4 majortechnical data
1.4.1 electrical system
media pump motor: power capacity is 9/11kw. rotatingspeed, 1440/2900 rpm. three phase, 380v，50hz.
separator motor: power capacity is 0.4kw. rotatingspeed, 2900 rpm. three phase, 380v，50hz.
turntable driving speed-regulating motor: power capacity is 0.75kw.rotating speed, 120～1200 rpm. three phase, 380v, 50hz.
lighting equipments: fluorescent lamps, 3×20w, a. c. 220v, 50hz.
total power consumption: about 12.5kw.
electrical supply: three phase 380v、50hz industrial power.
a steel conduit should be buried in advance to guidepower line to bottom of the main unit.
1.4.2 compressedair
pressure: 0.5-0.7mpa
air supply: dependingon customers need, use a hard pipe to connect with the air line in main unitvia a steel pipe buried in advance or connect an air hose (bore φ25mm, working pressure 0.8mpa) tothe main unit. air line of the machine is g1″.
air consumption of single gun: about 1.5m3/min
total consumption: about 7.5 m3/min。
1.4.3 cylinder
one set of cylinder combination with valve and switch
diameter 80mm. travel 250mm
1.4.4 processguns
4 pq-1 blast gun (oscillating)，4 pq-6 blast gun (hand-operated).nozzle diameter is 12.5mm.
1.4.5 storagesump capacity of the main unit is about 250l.
1.4.6 abrasivemedia
alumina in different grade sizebetween 46#～120# or glass bead smaller than 0.3mm.
charge ratio is 1:5 ～1:7 (dry abrasive: water)proportioned by weight.
1.4.7 watersupply
industrial tap water. depending on customers need, usea hard pipe to connect the industrial tap water supply with the water line inmain unit via a steel pipe buried in advance or connect an water delivery hose(bore φ13mm,working) to the main unit. water line of the machine is 1/2″.
consumption oftap water is not more than 0.3 m3 per shift.
1.4.8. turntablediameter: 1250mm.
1.4.9 max.external dimensions of whole unit: 3350×3380×2520 mm.
1.4.10 net weightof whole unit: 1500kg.
2. main componentsａnd principles
2.1 main unit system
main unit is the basic device for wet grit (or bead)blasting operation. the basic principle of blasting finish is jetting abrasiveliquid media to workpiece surface through a blast gun driven by media pump andcompressed air to fulfill a finish processing. the abrasive media is a mixtureof suitable grade-sized abrasive media and clean water added corrosion inhibitorin a certain ratio. depending on different nature of machined parts, we canchoose different man-made media such as quartz sand, glass bead, alumina or carborundum.media liquid should be filled in the storage sump reaching the level of theoverflow outlet on the upper part of sump.
blast process is performed in work cabinet. as the major componentto process blast directly, the process guns are connected with two line systemsof media and compressed air. during operation, the media pump carries abrasivemedia under certain pressure and flowing speed to the process gun from the unitstorage sump. meanwhile, a by-pass installed in the sump jets let out the medialiquid in high velocity through agitating nozzle, mixing water and abrasive insump evenly to keep the media pump work in efficiency. compressed air issupplied from outside via an electro-magnetic valve. there two choices forprocessing mode. one is that media is supplied by the media pump and blastedonto the workpiece surface after being accelerated by gun nozzle. another isthat process gun is offered media and compressed air by the pump and compressedair systems at the same time after their simultaneous starting and to jet anair-media flow at the workpiece surface after the mixing of media liquid andair in the gun. in this case, the cooperation of pump and air grants thejetting air-media flow a relatively high speed. as the kinetic energy ofabrasive particle wrapped by water is in direct ratio to the square of itsspeed, the process can get a better productivity effect than the one withoutcompressed air. with suitable abrasive media type, media grade size, chargeratio, jetting angle and distance, and other suitable related technicalparameters, we can process finish on complicated-shaped parts and the partswith high precision and smoothness. which can never be done by dryblast.
after blasting and grinding workpiece surface, the jetted mediadrops into the sump and from where it enters the media line system again. andthe finish process is a circulation of above procedure.
there is a damp valve in the air line which can adjust and fix thepressure of the outside connected compressed air as required. most of thecompressed air supplied to the process gun for blast, but also part of airenters a by-pass supplied to the combined cylinder with valve and switch andpneumatic wiper through a triple connector for air supply treatment.
the main unit is also equipped with outside connected water linewith industrial tap water. the line system has two by-passes. one is used tofill water in sump via a ball valve that can close the by-pass after the waterreaches overflow outlet. another is connected to a self-closing water gun.depress the switch lever on gun, water is jetted to wash workpiece and interiorof the main unit. lease the lever, jetting automatically stops. water jetted bythe self-closing water gun drops into the sump and will overflow from theoutlet to prevent the media pump (vertical) from faults caused by watersoaking.
2.2media collector system
media collector is a device for condensing media liquid andcollecting media. it can be used in the following situations. one is to collectthe original abrasive material for future reusing when the operation demands achange in the type and specification of abrasive. another is to refill newmedia when there is too much crushed abrasive media, which impairs operationeffect, after the media being used for a period. direct discharging will causea block in sewage. we should use the media collector to collect the wastedmedia and not let it enter the sewage directly during discharging.
to use the collector, we need to open the liquid entry valve that isgenerally shut and close the hose valve on the main unit abrasive media line.then, the media pumped out by the media pump flows into the tangential entry ofthe collector whirling drum via the liquid inlet valve, jetting into thewhirling drum in high speed. different centrifugal strength caused by thedifference of densities of water and abrasive in the media liquid make theouter media thicker and spirally deposit down to the bottom of the cone pipe.meanwhile the water of the media liquid assembles to the axle part of thewhirling drum and is pulled up by upwards force, overflowing from the outlet ontop of whirling drum and flowing back into the main unit sump via hose. then,after running the media pump for several minutes, stop it and open abrasiveoutlet valve of media deposit pot to collect the concentrated media withcontainer. repeat above circulation for 2～3 times, more than 90% abrasive in the media liquid can be collected(except the media stuck to dead corners and never entering the circulation).after collection, the inlet valve should be closed and the hose valve in themain unit media line should be opened.
2.3separator system
separator is a device for clearing grease and feeding back abrasivegrit supplied with the main unit.
separator is used when the media pump is not running.
media from the main unit sump enters the separator case via aconnecting hose and level of media equals to the top of grease extractionhopper. during the operation, grease from the media is floating on watersurface and discharged by the grease extraction hopper, flowing down to thesewage.
there is certain quantity of abrasive in the media liquidoverflowing into the separator case from the main unit outlet. this abrasivematerial deposits on the bottom of the separator case and is gathering more andmore as time passing. therewith, the charge ratio of the media liquid in themain unit sump will be effected and it has a negative effect on the process. tosolve this problem, water circulating pump system is set up in the separator.pumped from the case, water is divided into two lines. one flows back to themain unit pump via the ejecting nozzle in the t-way pipe connector. the mediathat deposits on the bottom of the separator case is suctioned up along theejecting hose by the ejecting nozzle, flowing back into the sump in this waterline in an almost unchanged charge ratio. another line is guided back to thebottom of the separator case via a hose for agitating, to help the ejectinghose feedback the media to the sump more efficiently.
wet bead blast (to reinforce part skin so as toincrease tensile strength and fatigue strength) and wet grit blast aredifferent in functions responding to different requirements. but theiroperation modes are the same.
2.4turntable
spinning of turntable is driven by a horizontalelectro-magnetic speed-regulating motor (speed regulated continuously in 120～1200rpm) with a power capacity of 0.75kw,a v-belt (1 : 2), a worm gear damper with speed reducing ratio of 1: 23 and asprocket-calibrated actuator about 1:10. minimum and maximum of rotating speedare listed as follows.
nmin=120×1/2×1/23×1/10= 0.26rpm
nmax=1200×1/2×1/23×1/10 =2.6rpm
that means the spinning of turntable can be tuned inthe range of about. 0.26～2.6rpm. controller of electro-magnetic speed-regulating motorinstalled on the control panel can be used for remote control.
2.5 oscillatinggun assembly
the machine has 4 oscillating guns, their fan-shaped oscillatingmotion driven by a combined cylinder with valve and switch. straightreciprocating motion of piston rod of cylinder is converted to oscillatingmotion by oscillating arm of the oscillating device. designed max oscillatingangle is 60°, which equals to the travel range of cylinder pistol of 220mm (thestandard travel range of cylinder is 250mm). moving range of oscillating gunset can change by adjusting the location of magnetic switch on the combinedcylinder. and tuning the silencing exhaust throttle valve on the cylinder canchange the moving speed of the gun set. it is easy to turn on and off theoscillating gun set by turning knobs on the control panel.
2.6electrical system
power supply of the machine is an industrial power supply ofthree-phase, 50hz and 380v with capacity of 12.5kw. it should be earthconnected for safety. air switch of suitable capacity should be set on thepower line connected to the machine for breaking circuit and safety protectingwhen maintaining electrical apparatuses of the machine. to connect the powerincoming wires and protection earth wire to the wiring terminals of l1, l2, l3,n and pe in the electrical box is ok.
main power supply switch qs is installed on the front side ofelectrical box. when the switch is on, lighting equipment is working.
there are over load protection, short protection, losing voltage andunder voltage protection on whole of three-phase load of the machine. whole ofone-phase load has short protection and over load protection. an e-stop buttonis also setup for breaking power supply when an emergency happens.
3. installation,tests and operation
3.1 installation and tests
1). according to externaldimensions of the machine, install it at suitable location in workshop. installthe outer guide track at the right side of main unit (refer to the arrangementdrawing). after matching up and leveling the outer and inner guide tracks, fixthem tightly to the main unit cabinet with bolts and rings, fittings of themachine. install the turntable on the outer guide track.
2). ditch a drainage connected tosewage at a required location according to the ss-10 wet blast machineinstallation location diagram.
3). check that the machine is notdamaged and intact with complete components and fittings.
4). connect water, power and airsupplies to the machine. install corresponding switches on all of the outerlines of these supplies.
5). connect pipes, hoses and wiresrelated to the main unit and its accessory equipments.
6). check the storage sump and thet-branch pipe at the bottom of the media pump in main unit for any extraneousmatter. clear the odd if there is any.
7). keep all valves and switches inthe “off” state.
8). close and secure the cabinetdoor.
note: the machine has a door-controlled switch. all buttons andknobs on control panels and “knee contact control box” can only work after thecabinet door being closed and secured. or else, components of the machinescannot work, such as media pump, separator pump, electro-magnetic valve of airline, electro-magnetic speed-regulating motor, and etc. therefore, the wrongoperation of wet blasting when door’s open can be avoided, which could endangerthe operator and machine.
9) test of the water line system
supply water to the water line of the machine. open the ball valvein the water line of the main unit to fill water into the storage sump andclose the valve when water level reaches the overflow outlet of the main unit.check main unit and separator everywhere for any leak. depress switch lever,the self-closing water gun should jet water. lease it, the water jetting stopsａnd no leakage happens.
10) circuit-closing test
connect to power supply and turn on the main power supply switch onthe electrical box, lighting system on roof of cabinet should light. open bothof the hose valves in the media line system and depress the media pump “start”button on the control panel (or push down the green “start” button on the “kneecontact control box”), motor is current-carrying and running. push down themedia pump “stop” button (or push down the red “stop” button on the “kneecontact control box”) immediately and check the rotating direction of themotor. viewed from the top of it, impeller rotating in clockwise, if not,correct it. with a correct rotating direction of the media pump motor, processgun should jet out water flow evenly.
note: the starting and closing down of media pump in the machine canbe either controlled separately by the “start” and “stop” buttons on the controlpanel or controlled by the green “start” and red “stop” buttons on the “kneecontact control box”.
11) air line test
supplyingair to the air line system of the machine, open the ball valve in the main unitair line and turn on the “process gun moving” knob on the control panel.therewith the cylinder works and drives the process guns to oscillate.
push downthe media pump “start” button on the control panel (or push down the green “start”button on the “knee contact control box”) and push down the “air supply” buttonon the control panel (or push down the black “air supply connected” button onthe “knee contact control box”). process gun will jet out a strong air-mediaflow. after seeing the strong jetting, push down the media pump “stop” buttonon the control panel (or push down the red “stop” button on the “knee contactcontrol box”).
note: the connection and closing of air supply for the machine canbe either controlled by the “air supply” buttons on the control panel or by theblack “air supply connected” and green “air supply closing” buttons on the “kneecontact control box”.
warning: during the test,hand-operated gun should be fixed if it’s not shut off or held by hａnd toprevent any unexpected danger.
12) turntable turning system test
turn on the “clutch” knob on thecontrol panel and push down the turntable “start” button on the control panel,the turntable should turn evenly and can be adjusted by the speed-regulating motor controller on the control panel.
after above tests, free from any fault or fault cleared out, wetblasting process can be started. if don’t want to use the machine at once, cutoff water, power, and air supplies and discharge water from the sump of themain unit.
3.2operation
3.2.1preparation
1). fill water into sump of themain unit (if necessary, adding “corrosion inhibitor” produced by our company.the detail measure for adding refers to the instruction of “corrosion inhibitor”).fill in the sump 50kg media, suitable type and grade-size to the requirement ofthe finish process. the weight proportion for abrasive and water is about 1:5.this ratio is not very critical and could be increased or reduced moderatelyaccording to the requirement of finish process.
2). load on the machined part.according to the location of it, adjust the position of the magnetic switch onthe combined cylinder and regulate the exhaustion volume of the silencingexhaust throttle valve to adjust the oscillating angle and moving speed of theprocess guns.
3). according to the finishrequirement, turn on (or off) the oscillating guns or hand-operated gun (byturning on or off the ball valve and hose valve in different air line and medialine separately corresponding to the oscillating guns and hand-operated gun).
warning: never change the position of themagnetic switch on the cylinder at will after adjustment.
3.2.2grit (or bead) blasting operation
warning:hand-operated gun should be fixed if it is not shut off or held in hａnd toprevent any unexpected danger.
1). close all cabinet doors.
2). turn on the pneumatic wiper,to-and-fro swinging rate of the wiper arm cannot be higher than 60 per minute.
3). turn the “media pump speedselect” knob to “low” or “high” position according to requirement, turn on theknobs of “clutch” and “process gun moving”.
4). push down the turntable “start” button on the control panel and adjustthe turning speed via the speed-regulating motorcontroller on the control panel. checkthat the oscillating range and speed of the guns are suitable.
5). push down the media pump “start”button on the control panel (or push down the green “start” button on the “kneecontact control box”), the motor running with its electrical supply connected.and then push down the “air supply” button on the control panel (or push downthe black “air supply connected” button on the “knee contact control box”).process gun should jet out an air-media flow evenly.
note: if any emergency happens, push downthe “emergency stop” (e-stop) button on the control panel (or push down the red “stop” button on the “knee contact control box”).
3.2.3end of operation
1). push down the media pump “stop”button on the control panel (or push down the red “stop” button on the “kneecontact control box”).
2). push down the “stop” button ofturntable turning and the one of water pump on the control panel. turn off the “processgun moving” knob.
3). unload workpiece and washinterior of the working cabinet with water gun.
4). close the pneumatic wiper.
5). cut off power supply and turnoff the switches in compressed air line and tap water line connected to themachine.
4. maintenance
4.1daily
1). examine appearance of the hosesresponsible for delivery of media and compressed air and check the condition ofconnections and seals.
2). check overflow outlet in themiddle of main unit for blockage.
3). check that the main unit liquidlevel reaches to the required height and fill in water accordingly.
4). check perforated grid board inmain unit for extraneous material on it.
5). open grease extraction valve ofthe separator and outside the floating grease away from the case.
4.2 every two weeks(or per 100 working hours)
1). the same as the items in “daily”.
2). wash the inside of the mainunit working cabinet and discharge all of the media in the storage sump(collected the used media by the collector). wash and clear the t-way pipesunder the sump and media pump. fill in fresh abrasive and water according torequirement.
3). also discharge water from theseparator case and wash the case.
4). check rubber protection glovesfor damage and replace or not according to their conditions.
4.3 every threemonths (or per 500 working hours)
1). the same as the items in “everytwo weeks”.
2). check the nozzle, one-way ballvalve, media delivery hose and air line of the process guns for blockage andwear. clear or replace according the conditions.
3). check bodies of the process gunsａnd rubber layer of the agitating nozzle for their wearing state. replace ornot according to the conditions and requirements.
4.4 every six months (or per1000 working hours)
1). the same as the items in “everythree months”.
2). dismantle and disassemble themedia pump. check the pump body, pump shell, impeller, extended shaft and pumpdischarging pipe for wear and replace or not according to the requirements. ifafraid that the rubber layer of the pump body will be worn out to expose themetal base before a next check of disassembly, should replace.
3). examine the rest parts,components and fastening pieces of all the electrical equipments and machine.
5. commonfault and remedy of ss-10 wet blast machine
fault
possible cause
remedy
1．no reaction after pushing down any button or switching on any knob.
①e-stop button is being pushed down.
②door is not shut firmly and the door-controlled switch is on protecting state.
①turn off e-stop button following the arrow direction shown on the button.
②close the cabinet door firmly.
2．media pump motor running but no media liquid pumped out
①a wrong rotating direction of motor.
②sump liquid level too low.
③leak in by-pass system.
④sump overloaded with media.
①change the rotating direction of motor. viewed from the top of motor, the correct direction is clockwise,
②fill water in sump until the level reaches the overflow outlet.
③check that the by-pass connection ａnd hoses are sealed.
④discharge and collect up all the media and fill in media to required charge ratio.
3．media pump is working but media pressure is too low.
①blockage in the line of pump inlet or outlet.
②media sump is overloaded with media.
③media agitation is not enough in the sump.
④impeller loosed or worn out badly.
⑤blockage in the media line connected with process gun.
①check out and clear blockage.
②collect up media and fill in media to required charge ratio.
③check out leakage, blockage or over-weary in by-pass and take suitable remedy in different case.
④tighten bolts on impeller to fix it or change impeller.
⑤find out the blockage and clear it.
4．charge ratio and level of sump media liquid are both correct but they are not circulating.
①air chocked in sump (always happening after exchange of media).
②possible caused by fault 2.
①open ball valve 1” connected to pump t-way assembly and restart the media pump. shut the valve after media is jetted out from process gun.
②resolve the fault according to the remedy of fault 2
5．media escaping from crack in the connection of pump top and motor flange.
①overflow outlet of sump blocked.
②blockage of exhaust vent on the top of working cabinet causes excessive pressure in cabinet.
③outlet pipe of media pump blocked.
find out and clear blockage
continued
fault
possible cause
remedy
6．some or all of fluorescent tubes of lighting equipment do not light
①wiring is loose or not correct.
②lamps damaged.
③amperite ballast damaged.
④fuse blown.
①check wiring.
②replace lamp.
③replace ballast.
④replace fuse.
7．excessive residual media in separator case.
①blockage in ejector or ejecting hose impairs or dispels the ejection.
②leak in ejecting hose impairs or dispels the ejection.
③lower end of the ejecting hose does not reach the cone bottom of the separator case.
④separator being operated when media pump running.
①check out ａnd clear the blockage
②check out and clear the leak.
③keep the end of the hose always at a correct location.
④use the separator when media pump closed down.
8．low flow rate or pressure of the media jetted out from process gun
①hose valve in the media line is not completely opened.
②media pump speed option knob on control panel is turned to the position of low speed.
①open the valve completely.
②turn the knob to the high speed position.
6. main electricaldevices list of ss-10 wet blast machine
no.
type
description
quantity
1
jd1aⅱ-40
speed-regulating motor controller
1
2
tpr4140 ac220v
switching-on clock
2
3
hh548 ac220v
control relay
5
4
tr51kx
control relay socket
5
5
rt18-32
fuse
5
6
ro15 2a
fuse core
2
7
ro15 4a
fuse core
2
8
ro15 6a
fuse core
1
9
3tb 4017 ac220v
a. c. excitation
3
10
3tb 4317 ac220v
a. c. excitation
3
11
3tb 4417 ac220v
a. c. excitation
1
12
3ve 1015 1.1～1.6
breaker
1
13
3ve 1015 1.6～2.5
breaker
1
14
c45ad-20-a3p
breaker
1
15
c45ad-25-a3p
breaker
1
16
c45ad-40-a4p
breaker
1
17
c45
leakage protection
1
18
hz12-40/08
supply switch
1
19
lay3-11 2s/11
e-stop button
1
20
lay3-11 （red）
switch button
3
21
lay3-11 （green）
switch button
5
22
lay3-11/z （black）
switch knob
4
23
p20j6a
round four-pin socket
2
24
25
26
27
28
7. main pneumaticcomponents list of ss-10 wet blast machine
no.
type
description
quantity
1
zcq-25 ac220v 50hz
electro-magnetic valve
1
2
ac3000-03
0.05-0.63mpa
triple connector for air supply treatment
1
3
ar5000-10
0.05-0.63mpa
pressure reducing valve
1
4
sc 80×250
combined cylinder with valve and switch [systematic integrate part 1]
1
8. consumable partslist of ss-10 wet blast machine
no.
type
description
quantity
1
pq6.2
gun nozzle
5
2
pq-1
process gun
4
3
pq-6
process gun
1
4
sb5a.1
upper pump case
1
5
sb5a.2
impeller
1
6
sb5a.3
bottom pump case
1
9. main extracomponents list of ss-10 wet blast machine
no.
type
description
quantity
1
yctg-112-4b 0.75kw
electro-magnetic speed-regulating motor
1
2
wcj120-23 down
worm gear damper
1
3
16a
stainless steel chain
136 sections
4
a889 gb1171-74
v-belt
2
5
sq-3
water gun
1
6
yd160 m-4/2 v1
9/11kw 50hz 380v
vertical bi-speed three-phase asynchronous motor
1
7
jcb 90
three-phase 380v 400w
pump motor
1
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一文读懂peacock孔雀测厚规使用方法
1.1 application
driven by media pumpandcompressed air, this machine is a new type of equipment specially designed forwet blast process utilized in finish.
the machine can clear castings andforgings, weldments, heat-treated parts, punched and machined workpieces andcan knock off the rough surface, oxide crust, remaining salt, burs, and etc. itcan be applied to do pre-treatment for coating and plating, high precision andhigh smoothness finish process on complicated-shaped components that othermethods cannot accomplish. it’s also very good at renovating used machinedparts.
1.2 features
1). dust pollution is effectivelyunder control during process.
2). no need of any extra ventilatorａnd dust remover, this machine can be directly installed on a product line soas to save working area and facilitate parts flowing.
3). with the variety of flexibleoperating methods and technological parameters, this machine is fit forrequirements of finish processing for parts made of different materials or invarious precisions.
4). the blasting process canimprove machined parts surface quality and reinforce parts skin so as toincrease wear-resistance and fatigue strength.
5). media consumption is limited.
6). major components of the machineare long-lived and are easy to be maintained
7). operator works in a low laborintensity with a high production efficiency.
1.3 buildup
the machinecomposed by main unit, outer guide track, media collector and separator asshown in ss-10 wet blast machine view, can be used in basic operation of thewet blast process and accessorial operations later.
1.4 majortechnical data
1.4.1 electrical system
media pump motor: power capacity is 9/11kw. rotatingspeed, 1440/2900 rpm. three phase, 380v，50hz.
separator motor: power capacity is 0.4kw. rotatingspeed, 2900 rpm. three phase, 380v，50hz.
turntable driving speed-regulating motor: power capacity is 0.75kw.rotating speed, 120～1200 rpm. three phase, 380v, 50hz.
lighting equipments: fluorescent lamps, 3×20w, a. c. 220v, 50hz.
total power consumption: about 12.5kw.
electrical supply: three phase 380v、50hz industrial power.
a steel conduit should be buried in advance to guidepower line to bottom of the main unit.
1.4.2 compressedair
pressure: 0.5-0.7mpa
air supply: dependingon customers need, use a hard pipe to connect with the air line in main unitvia a steel pipe buried in advance or connect an air hose (bore φ25mm, working pressure 0.8mpa) tothe main unit. air line of the machine is g1″.
air consumption of single gun: about 1.5m3/min
total consumption: about 7.5 m3/min。
1.4.3 cylinder
one set of cylinder combination with valve and switch
diameter 80mm. travel 250mm
1.4.4 processguns
4 pq-1 blast gun (oscillating)，4 pq-6 blast gun (hand-operated).nozzle diameter is 12.5mm.
1.4.5 storagesump capacity of the main unit is about 250l.
1.4.6 abrasivemedia
alumina in different grade sizebetween 46#～120# or glass bead smaller than 0.3mm.
charge ratio is 1:5 ～1:7 (dry abrasive: water)proportioned by weight.
1.4.7 watersupply
industrial tap water. depending on customers need, usea hard pipe to connect the industrial tap water supply with the water line inmain unit via a steel pipe buried in advance or connect an water delivery hose(bore φ13mm,working) to the main unit. water line of the machine is 1/2″.
consumption oftap water is not more than 0.3 m3 per shift.
1.4.8. turntablediameter: 1250mm.
1.4.9 max.external dimensions of whole unit: 3350×3380×2520 mm.
1.4.10 net weightof whole unit: 1500kg.
2. main componentsａnd principles
2.1 main unit system
main unit is the basic device for wet grit (or bead)blasting operation. the basic principle of blasting finish is jetting abrasiveliquid media to workpiece surface through a blast gun driven by media pump andcompressed air to fulfill a finish processing. the abrasive media is a mixtureof suitable grade-sized abrasive media and clean water added corrosion inhibitorin a certain ratio. depending on different nature of machined parts, we canchoose different man-made media such as quartz sand, glass bead, alumina or carborundum.media liquid should be filled in the storage sump reaching the level of theoverflow outlet on the upper part of sump.
blast process is performed in work cabinet. as the major componentto process blast directly, the process guns are connected with two line systemsof media and compressed air. during operation, the media pump carries abrasivemedia under certain pressure and flowing speed to the process gun from the unitstorage sump. meanwhile, a by-pass installed in the sump jets let out the medialiquid in high velocity through agitating nozzle, mixing water and abrasive insump evenly to keep the media pump work in efficiency. compressed air issupplied from outside via an electro-magnetic valve. there two choices forprocessing mode. one is that media is supplied by the media pump and blastedonto the workpiece surface after being accelerated by gun nozzle. another isthat process gun is offered media and compressed air by the pump and compressedair systems at the same time after their simultaneous starting and to jet anair-media flow at the workpiece surface after the mixing of media liquid andair in the gun. in this case, the cooperation of pump and air grants thejetting air-media flow a relatively high speed. as the kinetic energy ofabrasive particle wrapped by water is in direct ratio to the square of itsspeed, the process can get a better productivity effect than the one withoutcompressed air. with suitable abrasive media type, media grade size, chargeratio, jetting angle and distance, and other suitable related technicalparameters, we can process finish on complicated-shaped parts and the partswith high precision and smoothness. which can never be done by dryblast.
after blasting and grinding workpiece surface, the jetted mediadrops into the sump and from where it enters the media line system again. andthe finish process is a circulation of above procedure.
there is a damp valve in the air line which can adjust and fix thepressure of the outside connected compressed air as required. most of thecompressed air supplied to the process gun for blast, but also part of airenters a by-pass supplied to the combined cylinder with valve and switch andpneumatic wiper through a triple connector for air supply treatment.
the main unit is also equipped with outside connected water linewith industrial tap water. the line system has two by-passes. one is used tofill water in sump via a ball valve that can close the by-pass after the waterreaches overflow outlet. another is connected to a self-closing water gun.depress the switch lever on gun, water is jetted to wash workpiece and interiorof the main unit. lease the lever, jetting automatically stops. water jetted bythe self-closing water gun drops into the sump and will overflow from theoutlet to prevent the media pump (vertical) from faults caused by watersoaking.
2.2media collector system
media collector is a device for condensing media liquid andcollecting media. it can be used in the following situations. one is to collectthe original abrasive material for future reusing when the operation demands achange in the type and specification of abrasive. another is to refill newmedia when there is too much crushed abrasive media, which impairs operationeffect, after the media being used for a period. direct discharging will causea block in sewage. we should use the media collector to collect the wastedmedia and not let it enter the sewage directly during discharging.
to use the collector, we need to open the liquid entry valve that isgenerally shut and close the hose valve on the main unit abrasive media line.then, the media pumped out by the media pump flows into the tangential entry ofthe collector whirling drum via the liquid inlet valve, jetting into thewhirling drum in high speed. different centrifugal strength caused by thedifference of densities of water and abrasive in the media liquid make theouter media thicker and spirally deposit down to the bottom of the cone pipe.meanwhile the water of the media liquid assembles to the axle part of thewhirling drum and is pulled up by upwards force, overflowing from the outlet ontop of whirling drum and flowing back into the main unit sump via hose. then,after running the media pump for several minutes, stop it and open abrasiveoutlet valve of media deposit pot to collect the concentrated media withcontainer. repeat above circulation for 2～3 times, more than 90% abrasive in the media liquid can be collected(except the media stuck to dead corners and never entering the circulation).after collection, the inlet valve should be closed and the hose valve in themain unit media line should be opened.
2.3separator system
separator is a device for clearing grease and feeding back abrasivegrit supplied with the main unit.
separator is used when the media pump is not running.
media from the main unit sump enters the separator case via aconnecting hose and level of media equals to the top of grease extractionhopper. during the operation, grease from the media is floating on watersurface and discharged by the grease extraction hopper, flowing down to thesewage.
there is certain quantity of abrasive in the media liquidoverflowing into the separator case from the main unit outlet. this abrasivematerial deposits on the bottom of the separator case and is gathering more andmore as time passing. therewith, the charge ratio of the media liquid in themain unit sump will be effected and it has a negative effect on the process. tosolve this problem, water circulating pump system is set up in the separator.pumped from the case, water is divided into two lines. one flows back to themain unit pump via the ejecting nozzle in the t-way pipe connector. the mediathat deposits on the bottom of the separator case is suctioned up along theejecting hose by the ejecting nozzle, flowing back into the sump in this waterline in an almost unchanged charge ratio. another line is guided back to thebottom of the separator case via a hose for agitating, to help the ejectinghose feedback the media to the sump more efficiently.
wet bead blast (to reinforce part skin so as toincrease tensile strength and fatigue strength) and wet grit blast aredifferent in functions responding to different requirements. but theiroperation modes are the same.
2.4turntable
spinning of turntable is driven by a horizontalelectro-magnetic speed-regulating motor (speed regulated continuously in 120～1200rpm) with a power capacity of 0.75kw,a v-belt (1 : 2), a worm gear damper with speed reducing ratio of 1: 23 and asprocket-calibrated actuator about 1:10. minimum and maximum of rotating speedare listed as follows.
nmin=120×1/2×1/23×1/10= 0.26rpm
nmax=1200×1/2×1/23×1/10 =2.6rpm
that means the spinning of turntable can be tuned inthe range of about. 0.26～2.6rpm. controller of electro-magnetic speed-regulating motorinstalled on the control panel can be used for remote control.
2.5 oscillatinggun assembly
the machine has 4 oscillating guns, their fan-shaped oscillatingmotion driven by a combined cylinder with valve and switch. straightreciprocating motion of piston rod of cylinder is converted to oscillatingmotion by oscillating arm of the oscillating device. designed max oscillatingangle is 60°, which equals to the travel range of cylinder pistol of 220mm (thestandard travel range of cylinder is 250mm). moving range of oscillating gunset can change by adjusting the location of magnetic switch on the combinedcylinder. and tuning the silencing exhaust throttle valve on the cylinder canchange the moving speed of the gun set. it is easy to turn on and off theoscillating gun set by turning knobs on the control panel.
2.6electrical system
power supply of the machine is an industrial power supply ofthree-phase, 50hz and 380v with capacity of 12.5kw. it should be earthconnected for safety. air switch of suitable capacity should be set on thepower line connected to the machine for breaking circuit and safety protectingwhen maintaining electrical apparatuses of the machine. to connect the powerincoming wires and protection earth wire to the wiring terminals of l1, l2, l3,n and pe in the electrical box is ok.
main power supply switch qs is installed on the front side ofelectrical box. when the switch is on, lighting equipment is working.
there are over load protection, short protection, losing voltage andunder voltage protection on whole of three-phase load of the machine. whole ofone-phase load has short protection and over load protection. an e-stop buttonis also setup for breaking power supply when an emergency happens.
3. installation,tests and operation
3.1 installation and tests
1). according to externaldimensions of the machine, install it at suitable location in workshop. installthe outer guide track at the right side of main unit (refer to the arrangementdrawing). after matching up and leveling the outer and inner guide tracks, fixthem tightly to the main unit cabinet with bolts and rings, fittings of themachine. install the turntable on the outer guide track.
2). ditch a drainage connected tosewage at a required location according to the ss-10 wet blast machineinstallation location diagram.
3). check that the machine is notdamaged and intact with complete components and fittings.
4). connect water, power and airsupplies to the machine. install corresponding switches on all of the outerlines of these supplies.
5). connect pipes, hoses and wiresrelated to the main unit and its accessory equipments.
6). check the storage sump and thet-branch pipe at the bottom of the media pump in main unit for any extraneousmatter. clear the odd if there is any.
7). keep all valves and switches inthe “off” state.
8). close and secure the cabinetdoor.
note: the machine has a door-controlled switch. all buttons andknobs on control panels and “knee contact control box” can only work after thecabinet door being closed and secured. or else, components of the machinescannot work, such as media pump, separator pump, electro-magnetic valve of airline, electro-magnetic speed-regulating motor, and etc. therefore, the wrongoperation of wet blasting when door’s open can be avoided, which could endangerthe operator and machine.
9) test of the water line system
supply water to the water line of the machine. open the ball valvein the water line of the main unit to fill water into the storage sump andclose the valve when water level reaches the overflow outlet of the main unit.check main unit and separator everywhere for any leak. depress switch lever,the self-closing water gun should jet water. lease it, the water jetting stopsａnd no leakage happens.
10) circuit-closing test
connect to power supply and turn on the main power supply switch onthe electrical box, lighting system on roof of cabinet should light. open bothof the hose valves in the media line system and depress the media pump “start”button on the control panel (or push down the green “start” button on the “kneecontact control box”), motor is current-carrying and running. push down themedia pump “stop” button (or push down the red “stop” button on the “kneecontact control box”) immediately and check the rotating direction of themotor. viewed from the top of it, impeller rotating in clockwise, if not,correct it. with a correct rotating direction of the media pump motor, processgun should jet out water flow evenly.
note: the starting and closing down of media pump in the machine canbe either controlled separately by the “start” and “stop” buttons on the controlpanel or controlled by the green “start” and red “stop” buttons on the “kneecontact control box”.
11) air line test
supplyingair to the air line system of the machine, open the ball valve in the main unitair line and turn on the “process gun moving” knob on the control panel.therewith the cylinder works and drives the process guns to oscillate.
push downthe media pump “start” button on the control panel (or push down the green “start”button on the “knee contact control box”) and push down the “air supply” buttonon the control panel (or push down the black “air supply connected” button onthe “knee contact control box”). process gun will jet out a strong air-mediaflow. after seeing the strong jetting, push down the media pump “stop” buttonon the control panel (or push down the red “stop” button on the “knee contactcontrol box”).
note: the connection and closing of air supply for the machine canbe either controlled by the “air supply” buttons on the control panel or by theblack “air supply connected” and green “air supply closing” buttons on the “kneecontact control box”.
warning: during the test,hand-operated gun should be fixed if it’s not shut off or held by hａnd toprevent any unexpected danger.
12) turntable turning system test
turn on the “clutch” knob on thecontrol panel and push down the turntable “start” button on the control panel,the turntable should turn evenly and can be adjusted by the speed-regulating motor controller on the control panel.
after above tests, free from any fault or fault cleared out, wetblasting process can be started. if don’t want to use the machine at once, cutoff water, power, and air supplies and discharge water from the sump of themain unit.
3.2operation
3.2.1preparation
1). fill water into sump of themain unit (if necessary, adding “corrosion inhibitor” produced by our company.the detail measure for adding refers to the instruction of “corrosion inhibitor”).fill in the sump 50kg media, suitable type and grade-size to the requirement ofthe finish process. the weight proportion for abrasive and water is about 1:5.this ratio is not very critical and could be increased or reduced moderatelyaccording to the requirement of finish process.
2). load on the machined part.according to the location of it, adjust the position of the magnetic switch onthe combined cylinder and regulate the exhaustion volume of the silencingexhaust throttle valve to adjust the oscillating angle and moving speed of theprocess guns.
3). according to the finishrequirement, turn on (or off) the oscillating guns or hand-operated gun (byturning on or off the ball valve and hose valve in different air line and medialine separately corresponding to the oscillating guns and hand-operated gun).
warning: never change the position of themagnetic switch on the cylinder at will after adjustment.
3.2.2grit (or bead) blasting operation
warning:hand-operated gun should be fixed if it is not shut off or held in hａnd toprevent any unexpected danger.
1). close all cabinet doors.
2). turn on the pneumatic wiper,to-and-fro swinging rate of the wiper arm cannot be higher than 60 per minute.
3). turn the “media pump speedselect” knob to “low” or “high” position according to requirement, turn on theknobs of “clutch” and “process gun moving”.
4). push down the turntable “start” button on the control panel and adjustthe turning speed via the speed-regulating motorcontroller on the control panel. checkthat the oscillating range and speed of the guns are suitable.
5). push down the media pump “start”button on the control panel (or push down the green “start” button on the “kneecontact control box”), the motor running with its electrical supply connected.and then push down the “air supply” button on the control panel (or push downthe black “air supply connected” button on the “knee contact control box”).process gun should jet out an air-media flow evenly.
note: if any emergency happens, push downthe “emergency stop” (e-stop) button on the control panel (or push down the red “stop” button on the “knee contact control box”).
3.2.3end of operation
1). push down the media pump “stop”button on the control panel (or push down the red “stop” button on the “kneecontact control box”).
2). push down the “stop” button ofturntable turning and the one of water pump on the control panel. turn off the “processgun moving” knob.
3). unload workpiece and washinterior of the working cabinet with water gun.
4). close the pneumatic wiper.
5). cut off power supply and turnoff the switches in compressed air line and tap water line connected to themachine.
4. maintenance
4.1daily
1). examine appearance of the hosesresponsible for delivery of media and compressed air and check the condition ofconnections and seals.
2). check overflow outlet in themiddle of main unit for blockage.
3). check that the main unit liquidlevel reaches to the required height and fill in water accordingly.
4). check perforated grid board inmain unit for extraneous material on it.
5). open grease extraction valve ofthe separator and outside the floating grease away from the case.
4.2 every two weeks(or per 100 working hours)
1). the same as the items in “daily”.
2). wash the inside of the mainunit working cabinet and discharge all of the media in the storage sump(collected the used media by the collector). wash and clear the t-way pipesunder the sump and media pump. fill in fresh abrasive and water according torequirement.
3). also discharge water from theseparator case and wash the case.
4). check rubber protection glovesfor damage and replace or not according to their conditions.
4.3 every threemonths (or per 500 working hours)
1). the same as the items in “everytwo weeks”.
2). check the nozzle, one-way ballvalve, media delivery hose and air line of the process guns for blockage andwear. clear or replace according the conditions.
3). check bodies of the process gunsａnd rubber layer of the agitating nozzle for their wearing state. replace ornot according to the conditions and requirements.
4.4 every six months (or per1000 working hours)
1). the same as the items in “everythree months”.
2). dismantle and disassemble themedia pump. check the pump body, pump shell, impeller, extended shaft and pumpdischarging pipe for wear and replace or not according to the requirements. ifafraid that the rubber layer of the pump body will be worn out to expose themetal base before a next check of disassembly, should replace.
3). examine the rest parts,components and fastening pieces of all the electrical equipments and machine.
5. commonfault and remedy of ss-10 wet blast machine
fault
possible cause
remedy
1．no reaction after pushing down any button or switching on any knob.
①e-stop button is being pushed down.
②door is not shut firmly and the door-controlled switch is on protecting state.
①turn off e-stop button following the arrow direction shown on the button.
②close the cabinet door firmly.
2．media pump motor running but no media liquid pumped out
①a wrong rotating direction of motor.
②sump liquid level too low.
③leak in by-pass system.
④sump overloaded with media.
①change the rotating direction of motor. viewed from the top of motor, the correct direction is clockwise,
②fill water in sump until the level reaches the overflow outlet.
③check that the by-pass connection ａnd hoses are sealed.
④discharge and collect up all the media and fill in media to required charge ratio.
3．media pump is working but media pressure is too low.
①blockage in the line of pump inlet or outlet.
②media sump is overloaded with media.
③media agitation is not enough in the sump.
④impeller loosed or worn out badly.
⑤blockage in the media line connected with process gun.
①check out and clear blockage.
②collect up media and fill in media to required charge ratio.
③check out leakage, blockage or over-weary in by-pass and take suitable remedy in different case.
④tighten bolts on impeller to fix it or change impeller.
⑤find out the blockage and clear it.
4．charge ratio and level of sump media liquid are both correct but they are not circulating.
①air chocked in sump (always happening after exchange of media).
②possible caused by fault 2.
①open ball valve 1” connected to pump t-way assembly and restart the media pump. shut the valve after media is jetted out from process gun.
②resolve the fault according to the remedy of fault 2
5．media escaping from crack in the connection of pump top and motor flange.
①overflow outlet of sump blocked.
②blockage of exhaust vent on the top of working cabinet causes excessive pressure in cabinet.
③outlet pipe of media pump blocked.
find out and clear blockage
continued
fault
possible cause
remedy
6．some or all of fluorescent tubes of lighting equipment do not light
①wiring is loose or not correct.
②lamps damaged.
③amperite ballast damaged.
④fuse blown.
①check wiring.
②replace lamp.
③replace ballast.
④replace fuse.
7．excessive residual media in separator case.
①blockage in ejector or ejecting hose impairs or dispels the ejection.
②leak in ejecting hose impairs or dispels the ejection.
③lower end of the ejecting hose does not reach the cone bottom of the separator case.
④separator being operated when media pump running.
①check out ａnd clear the blockage
②check out and clear the leak.
③keep the end of the hose always at a correct location.
④use the separator when media pump closed down.
8．low flow rate or pressure of the media jetted out from process gun
①hose valve in the media line is not completely opened.
②media pump speed option knob on control panel is turned to the position of low speed.
①open the valve completely.
②turn the knob to the high speed position.
6. main electricaldevices list of ss-10 wet blast machine
no.
type
description
quantity
1
jd1aⅱ-40
speed-regulating motor controller
1
2
tpr4140 ac220v
switching-on clock
2
3
hh548 ac220v
control relay
5
4
tr51kx
control relay socket
5
5
rt18-32
fuse
5
6
ro15 2a
fuse core
2
7
ro15 4a
fuse core
2
8
ro15 6a
fuse core
1
9
3tb 4017 ac220v
a. c. excitation
3
10
3tb 4317 ac220v
a. c. excitation
3
11
3tb 4417 ac220v
a. c. excitation
1
12
3ve 1015 1.1～1.6
breaker
1
13
3ve 1015 1.6～2.5
breaker
1
14
c45ad-20-a3p
breaker
1
15
c45ad-25-a3p
breaker
1
16
c45ad-40-a4p
breaker
1
17
c45
leakage protection
1
18
hz12-40/08
supply switch
1
19
lay3-11 2s/11
e-stop button
1
20
lay3-11 （red）
switch button
3
21
lay3-11 （green）
switch button
5
22
lay3-11/z （black）
switch knob
4
23
p20j6a
round four-pin socket
2
24
25
26
27
28
7. main pneumaticcomponents list of ss-10 wet blast machine
no.
type
description
quantity
1
zcq-25 ac220v 50hz
electro-magnetic valve
1
2
ac3000-03
0.05-0.63mpa
triple connector for air supply treatment
1
3
ar5000-10
0.05-0.63mpa
pressure reducing valve
1
4
sc 80×250
combined cylinder with valve and switch [systematic integrate part 1]
1
8. consumable partslist of ss-10 wet blast machine
no.
type
description
quantity
1
pq6.2
gun nozzle
5
2
pq-1
process gun
4
3
pq-6
process gun
1
4
sb5a.1
upper pump case
1
5
sb5a.2
impeller
1
6
sb5a.3
bottom pump case
1
9. main extracomponents list of ss-10 wet blast machine
no.
type
description
quantity
1
yctg-112-4b 0.75kw
electro-magnetic speed-regulating motor
1
2
wcj120-23 down
worm gear damper
1
3
16a
stainless steel chain
136 sections
4
a889 gb1171-74
v-belt
2
5
sq-3
water gun
1
6
yd160 m-4/2 v1
9/11kw 50hz 380v
vertical bi-speed three-phase asynchronous motor
1
7
jcb 90
three-phase 380v 400w
pump motor
1
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