How to Choose Equipment for Shot Blasting
LLC «Intellectual Robot Systems» presents a modern technology for automated shot/sand blasting of surface parts of assembly units. One of the most important technological stages in creating high-tech products is surface strengthening, or SHOT PEENING.
Solutions for Automated Shot/Sand Blasting of Surface Parts of Assembly Units
The SHOT PEENING technology is a modern shot blasting method widely used in aerospace, automotive, and other industries to remove machining defects, protect against surface fatigue stresses, prepare surfaces for functional coatings by jet impact of shot on the workpiece surface, as well as for plastic bending of thin sheet materials. Parts can be processed using steel, plastic, glass, or ceramic shot.
This type of treatment, by impacting the metal surface with shot with sufficient force to create plastic deformation, generates controlled compressive stress in the surface layer, improving the mechanical properties of surface layers, increasing fatigue strength, and extending the part's service life while preventing galling, cracks, and corrosion.
Type of shot: metallic, glass, ceramic, plastic balls, or spherical cut wire (sccw).
Applications
In industry: gearbox components, main and crank shafts, leaf springs and coil springs, torsion bars, sprockets, gears and pinions, clutch springs, driveshaft components, lever mechanisms, valve springs and parts, transmission elements, synchronizer rings, inter-axle differentials, gear shafts, axles and bearings, connecting rods, rollers and support surfaces, pistons, piston pins, punches, drill rods, drilling rig parts, drilling tools, and more.
In the aerospace industry: turbine blades and other aviation turbine components, compressor blades, monowheels, blings and blisks of turbofan engines, aircraft components, landing gear, and other critical aircraft and helicopter parts, wing skin and stringer shaping, achieving required geometry, curvature, and aerodynamic smoothness.
«Intellectual Robot Systems» develops, manufactures, and supplies automated systems according to the Customer’s technical requirements, taking into account all necessary functions and technological solutions.
At the Customer's request, automated systems can also be equipped with additional equipment and tooling, such as:
CNC System for Shot Blasting with Glass or Ceramic Shot
Designed for efficient strengthening of aviation engine components. Creates controlled compressive stress on the part surface to improve surface properties, increase fatigue strength, extend component life, and prevent wear, cracks, and corrosion.
The system can process parts up to 48″ (1220 mm) in length.
- SYSTEM FEATURES:
- 2-axis servo drive for reciprocating motion
- Adjustable rotary table speed
- Enlarged tank volume for long processing periods
- Fast and precise positioning of 6 shot nozzles
- Color touchscreen Siemens
- High-performance shot regenerator
- Convenient clamping fixtures
- Optional:
- Automatic feeder
- Closed-loop air pressure control system
- Magnetic separator
- Drive lance nozzle
- Spiral-type separator
- Vibratory screening unit
- Motorized loading/unloading table
CNC System for Shot Blasting with Ceramic Shot
Designed for processing 3–5 gas turbine blades simultaneously. Creates controlled compressive stress on the part surface to improve surface properties, increase fatigue strength, enhance lubricity, extend component life, and prevent wear, cracks, and corrosion.
The system can process parts up to 1000 mm in length and 500 mm in width.
SYSTEM FEATURES:- Standard:
- Large working space in the chamber
- 2-axis programmable servo drive for gun movement
- 5 rotary tables for simultaneous processing
- Convenient loading/unloading of parts outside the chamber
- Adjustable table rotation speed for varying strengthening intensity
- Very high machine productivity
- Vibratory screening unit
- Fast and precise positioning of 15 shot nozzles
- Independent control of shot nozzles
- Color touchscreen Siemens
- Pneumatic recovery system
- Mechanical recovery system
- High-performance shot regenerator
- Convenient clamping fixtures
- Closed-loop air pressure control system
- Optional:
- Automatic feeder
- Spiral-type separator
- Second door with rotary table as the 8th robot axis
- Custom-made clamping fixtures
The chamber is equipped with a fully automated abrasive collection, cleaning, and recycling system, including a vibratory screening system, hoppers, pressure generator, and other mechanisms.
The floor grid is made of 6 mm steel and is rated for a load of 600 kg. The grid is not designed for transporting machinery, forklifts, etc. The spacing between grid elements prevents hand tools from passing through during transport.
The abrasive is transported via bucket elevator to the screening system.
The screening system is made of stainless steel and has 3 sections. Abrasive from the top and bottom sections goes to the waste collector, while the second section feeds the storage hopper for reuse.
The system is equipped with a 1.5 kW drive.
The storage hopper, with a capacity of approximately 0.2 m3, is made of 6 mm steel.
The pressure generator consists of upper and lower generators with capacities of 0.085 m3 and 0.14 m3, made of 6 mm steel and hydraulically tested at 17 bar.
Brief technical specifications:- Output valve: automatic with silencer
- Compressed air connection: 1.5″ BSP with
- required flow of 4600 l/min at 7 bar
- Operating pressure: 1–6 bar
- The generator is equipped with necessary valves for pressure build-up and release.
The abrasive is then supplied to the nozzle via a wear-resistant antistatic hose with an internal diameter of 25 mm.
Control System
The control system is based on an industrial programmable controller Siemens S7-1200 with a color touchscreen, allowing remote diagnostics of equipment malfunctions.
Main control panel functions:- Emergency stop control
- Control of all motors
- Control of all control subsystems
- Monitoring of all interlock keys
- Manual and automatic process control
- Automatic control — for part types with established processing technology
- Manual control — for programming processing technology
- Step-by-step control of robot and rotator movements
- If processing stops for any reason, the system can return the gun to its initial position and resume from the stopping point after troubleshooting
Operator Panel
The operator panel has an intuitive interface for managing:
- Functions:
- 10″ color touchscreen
- Switching auto/manual operation modes
- Manual programming of robot movements
- Adding new processing modes
- Loading pre-established processing modes for parts
- Error messages
- Resetting error messages
- Emergency stop
- Start of processing cycle
- End of processing cycle
- Indicators:
- Emergency stop
- Power on/off
- On/off status of all robot movements, rotator, dust collector, etc.
- System readiness
- Monitoring:
- Air pressure
- Rotator speed in real time
- Robot gun movement in real time
- Selected processing modes
- Upper and lower limits of operating pressure
- Position of robot linear carriage
- Status of exhaust fan operation
- Status of recovery system operation
- Status of separation system operation
- Status of ventilation system operation
- Door lock status
- Filter status
- Working time counter with reset option
Example of Finished Solution
Automated System for Strengthening Drill Pipe Surfaces
Allows creating controlled compressive stress on the blade surface to improve surface layer properties, increase fatigue strength, enhance lubricity, and consequently extend overall pipe life, preventing premature wear, corrosion, and cracking.
The system can process pipes up to 12″ (305 mm) in diameter and 12 m in length.
Manual System for Strengthening Drill Pipe Surfaces
Allows creating controlled compressive stress on the blade surface to improve surface layer properties, increase fatigue strength, enhance lubricity, and consequently extend overall pipe life, preventing premature wear, corrosion, and cracking.
Our company is a developer and manufacturer of surface treatment equipment. Our philosophy of continuous improvement and close collaboration with clients, combined with flexible production and service capabilities, allows us to create customized products and processes to support clients from start to finish.
Our clients are always satisfied — we offer the best solutions on the market.
- In addition to providing remote technical support, we organize on-site visits by our specialists if needed.
- We also provide staff training services on our equipment.
- After equipment delivery, we provide the full range of warranty and service support.
- Over 15 years, due to high service quality, professionalism, and an individual approach to clients, we have become one of the leaders in the Russian market in our field and earned the trust of leading enterprises in aerospace, defense, nuclear, and oil industries, as evidenced by numerous letters of appreciation.
- We value our clients and provide even more than stated in the contract. Our client is not just a customer, but a full partner and Friend. This is a fundamental principle of our company.
