我公司原用通過式懸掛拋丸機對客戶的鍛件進行表面拋丸處理，該設備因是傳統的通過式，拋丸室進出口靠多層皮子擋鋼丸，造成密封不嚴，設備漏砂嚴重，鋼丸收回比例低，造成鍛件拋丸后表面不光滑，發烏發暗，影響鍛件表面質量。本文結合公司幾十年鍛件生產經驗和技術積累，總結出提升鍛件表面拋丸質量幾點要素，設計、制造了步進式懸掛拋丸機，滿足產品質量要求，提高了產品市場競爭力。新拋丸機采用自動化控制，噴丸效率提升，同時節約了人工成本。

　　Our company originally used a through type suspension shot blasting machine to perform surface shot blasting treatment on customers' forgings. Due to the traditional through type equipment, the entrance and exit of the shot blasting chamber rely on multiple layers of leather to block the steel shot, resulting in poor sealing, severe sand leakage, and low steel shot recovery ratio. This causes the surface of the forgings to be uneven, black and dark after shot blasting, affecting the surface quality of the forgings. This article combines the company's decades of experience and technological accumulation in forging production to summarize several elements for improving the surface shot blasting quality of forgings. A stepper suspension shot blasting machine has been designed and manufactured to meet product quality requirements and enhance product market competitiveness. The new shot blasting machine adopts automated control, which improves shot blasting efficiency and saves labor costs.

　　新拋丸機簡介

　　Introduction to the new shot blasting machine

　　拋丸機工作流程

　　Shot blasting machine workflow

　　拋丸工作流程見圖1。拋丸機由PLC 控制，除塵器、彈丸循環系統啟動運行，等待生產。上料區操作工通過懸臂吊裝料后，通過懸鏈輸送系統將待處理鍛件送至拋丸室內待噴區域后停止，拋丸室門關閉，自轉系統開啟，在自轉機構的驅動下，吊鉤總成帶著零件以鏈輪傳動的方式旋轉，此時拋丸器與彈丸閘門打開，拋丸清理旋轉的鍛件。自轉機構加裝變頻器，通過調節變頻器來控制自轉速度大小來保證鍛件拋丸無盲區。

　　The shot blasting workflow is shown in Figure 1. The shot blasting machine is controlled by PLC, and the dust collector and shot circulation system start running, waiting for production. After the loading area operator uses a cantilever crane to load materials, the forging to be processed is transported to the spraying area in the shot blasting room through a chain conveyor system and then stopped. The shot blasting room door is closed, and the self rotation system is opened. Under the drive of the self rotation mechanism, the hook assembly rotates with the parts in a chain wheel drive manner. At this time, the shot blasting machine and shot blasting gate open, and the rotating forging is shot blasted and cleaned. Install a frequency converter on the rotation mechanism, and control the rotation speed by adjusting the frequency converter to ensure that the forging shot blasting has no blind spots.

　　清理完畢，彈丸閘門和拋丸器關閉，拋丸室大門打開，自轉裝置停止，懸鏈輸送系統將清理區域內的鍛件傳送出拋丸室，同時等待區上的鍛件快速進入拋丸室，關閉拋丸室，開啟自轉裝置帶動鍛件旋轉，開啟拋丸器下料閘門，開始下一次清理工作。操作工在上/卸料區同時進行裝卸作業。

　　After cleaning, the shot blasting gate and shot blasting device are closed, the shot blasting chamber door is opened, the rotation device stops, and the suspension chain conveying system transports the forgings in the cleaning area out of the shot blasting chamber. At the same time, the forgings in the waiting area quickly enter the shot blasting chamber. Close the shot blasting chamber, open the rotation device to drive the forgings to rotate, open the shot blasting device discharge gate, and start the next cleaning work. Operators carry out loading and unloading operations simultaneously in the loading/unloading area.

　　懸掛拋丸機主要結構及特點

　　Main structure and characteristics of suspended shot blasting machine

　　拋丸機容量按調質爐鍛件日產量設計為雙工位懸鏈步進式拋丸清理機，主要由鍛件懸鏈系統、拋丸室、彈丸循環系統、掛具自轉系統、電氣控制系統、除塵系統等組成。

　　The capacity of the shot blasting machine is designed as a dual station catenary walking shot blasting cleaning machine based on the daily production of quenched and tempered furnace forgings. It mainly consists of a forging catenary system, shot blasting chamber, shot circulation system, hanging tool rotation system, electrical control system, dust removal system, etc.

　　⑴鍛件懸鏈系統。拋丸機懸鏈系統選用2 寸模鍛鏈條，每個吊鉤由兩組負載滑架承載。被清理鍛件通過掛具吊掛在吊鉤上，懸鏈系統由驅動鏈輪帶動，使鍛件沿軌道步進式地行進。懸鏈走輪在工字鋼下翼上運行，導輪用來防止吊鉤進入拋丸器工作區時產生擺動。吊鉤總成根據生產需要及場地限制設計10 個，每2 個一組，后期可根據需要增加數量。吊鉤上側加裝一層下凹式的錳鋼板，與一層軋制Mn13 高耐磨護板、多層耐磨膠板及清理室頂部掛鉤行走槽處的尼龍毛刷共同組成迷宮式密封帶，在有效防止彈丸反彈到室外的同時，防止鋼砂對鏈條及走輪的損傷。

　　⑴ Forging suspension chain system. The suspension chain system of the shot blasting machine uses 2-inch forged chains, and each hook is supported by two sets of load slides. The cleaned forging is hung on a hook by a hanging device, and the suspension chain system is driven by a sprocket to move the forging step by step along the track. The hanging chain running wheel runs on the lower wing of the I-beam, and the guide wheel is used to prevent the hook from swinging when entering the working area of the shot blasting machine. 10 hook assemblies are designed according to production needs and site limitations, with each set consisting of 2 hooks. The quantity can be increased as needed in the later stage. A layer of concave manganese steel plate is installed on the upper side of the hook, which, together with a layer of rolled Mn13 high wear-resistant protective plate, multiple layers of wear-resistant rubber plates, and a nylon brush at the top of the cleaning room hook walking groove, forms a labyrinth sealing belt. It effectively prevents bullets from bouncing outside and prevents steel sand from damaging the chain and wheels.

　　⑵拋丸清理室。拋丸室體由型鋼制成骨架，外側用普通鋼板條焊接而成，內側用軋制錳鋼焊接。拋丸室的鋼結構件均要求設備廠家噴丸清理后噴防銹底漆，同時還具有強化時效功能，保證有足夠的剛度和強度。室體內襯拋射熱區為18mm 厚軋制Mn13 耐磨護板，非熱區為14mm 厚軋制Mn13 耐磨護板，采用大塊焊接方式固定，方便后期維護。拋丸室體頂部掛鉤走槽采用成熟的迷宮式密封方法，結構精細，可最大限度地防止拋射的鋼丸飛出拋丸室。清理室內設有地坪格柵，便于維修人員行走，并在格柵上鋪設鑄鉻耐磨沖孔護板，防止較大塊狀物、飛邊、毛刺進入漏斗、螺旋輸送器和提升機，確保彈丸的正常循環，保證設備運轉正常。拋丸室兩側進出口設有氣動對開門，采用帶緩沖裝置的氣缸驅動，大門開、閉平穩，無沖擊，同時氣缸上設有光電接收器，起聯鎖保護作用。拋丸室門采用10mm 厚軋制Mn13 護板保護，并在門框一圈設置環形橡膠防護，防止鋼丸飛濺。拋丸室大門底部設有彈丸回收槽，方便開門時夾雜在門縫中的殘留鋼丸回收到室體內，防止彈丸四處散落，并達到彈丸回收利用的作用。

　　⑵ Shot blasting cleaning room. The shot blasting chamber body is made of profile steel skeleton, the outer side is welded with ordinary steel plates, and the inner side is welded with rolled manganese steel. The steel structural components of the shot blasting room require the equipment manufacturer to spray anti rust primer after shot blasting cleaning, and also have enhanced aging function to ensure sufficient rigidity and strength. The interior lining of the room is equipped with 18mm thick rolled Mn13 wear-resistant protective plate in the hot zone, and 14mm thick rolled Mn13 wear-resistant protective plate in the non hot zone. It is fixed by large welding to facilitate later maintenance. The hanging groove on the top of the shot blasting chamber adopts a mature labyrinth sealing method, with a fine structure that can prevent the ejected steel shot from flying out of the shot blasting chamber to the maximum extent. Clean the indoor floor grid for maintenance personnel to walk, and lay chrome wear-resistant punched protective plates on the grid to prevent large objects, flying edges, and burrs from entering the funnel, screw conveyor, and elevator, ensuring the normal circulation of pellets and the normal operation of equipment. Pneumatic double doors are installed at the entrances and exits on both sides of the shot blasting room, driven by cylinders with buffering devices. The doors open and close smoothly without impact. At the same time, photoelectric receivers are installed on the cylinders to provide interlocking protection. The shot blasting room door is protected by a 10mm thick rolled Mn13 guard plate, and a circular rubber protection is installed around the door frame to prevent steel shot splashing. The bottom of the shot blasting room door is equipped with a shot recovery groove, which facilitates the recovery of residual steel shot mixed in the door gap when opening the door, preventing the shot from scattering around and achieving the purpose of shot recovery and utilization.

　　⑶拋丸器總成。拋丸器布置方式經過設計團隊多次研討，在并列3 組6 臺方式和并列2 組6 臺方式之間進行取舍，由于現場空間受限及鍛件長度決定，最終確認拋丸室側壁上設計成并列2 組6 臺拋丸器總成的布局(如零件長超過1300mm，建議采用2 組6 臺方式；如果是正常6 缸曲軸類零件，建議使用3 組6 臺方式)，將拋丸盲區降到最低。拋丸器電機采用西門子品牌，性能穩定可靠，根據老式拋丸機使用反饋經驗，并結合制造廠商測算，拋丸量定在360kg/min，電機功率為22kW。新拋丸器舍棄主流的直連方式，而是采用皮帶傳動結構。根據十幾年拋丸器使用經驗證明，直連式拋丸機雖效率高，但是維護不方便，電機易損壞，采用皮帶傳動拋丸器，方便日常維護維修，同時降低拋丸器采購成本，拋丸效率可通過傳動速比進行補償。拋丸器外殼采用錳鋼制成，側面外殼鋼板厚12mm，軸承端面和對面外殼鋼板厚14mm，端蓋鋼板厚度可采用10mm。拋丸器內部零部件護板、定向套、分丸輪、葉片、葉輪等均采用現今流行的模具鋼CNC 精密加工，加工精度達到±0.01mm。要求機加工后采用低壓真空熱處理方式，硬度為58 ～62HRC，硬度偏上，達到60 ～62HRC 為最佳，增加零部件耐磨度，若超過62HRC 零部件發脆，易斷。經現場使用驗證，使用丸料為φ1.5mm 以下鑄鋼丸(鋼丸過大易損葉片，特別是鋼絲切丸)，以上易損件使用壽命是鑄造產品三倍以上。

　　⑶ Shot blasting machine assembly. After multiple discussions by the design team, the layout of the shot blasting equipment was chosen between the parallel 3 sets of 6 units and the parallel 2 sets of 6 units. Due to limited space on site and the length of the forgings, it was finally confirmed that the side walls of the shot blasting room should be designed with a layout of 2 sets of 6 shot blasting equipment assemblies in parallel (if the length of the parts exceeds 1300mm, it is recommended to use 2 sets of 6 units); If it is a normal 6-cylinder crankshaft component, it is recommended to use 3 sets of 6 units to minimize the shot blasting blind spot. The shot blasting machine motor adopts Siemens brand, with stable and reliable performance. Based on feedback from the use of old shot blasting machines and combined with manufacturer calculations, the shot blasting volume is set at 360kg/min, and the motor power is 22kW. The new shot blasting machine abandons the mainstream direct connection method and adopts a belt transmission structure. Based on more than a decade of experience using shot blasting machines, it has been proven that although direct connected shot blasting machines have high efficiency, they are not easy to maintain and the motor is prone to damage. Therefore, belt driven shot blasting machines are used to facilitate daily maintenance and repair, while reducing the cost of shot blasting equipment procurement. Shot blasting efficiency can be compensated by the transmission speed ratio. The shell of the shot blasting machine is made of manganese steel, with a thickness of 12mm for the side shell steel plate, 14mm for the bearing end face and the opposite shell steel plate, and 10mm for the end cover steel plate. The internal components of the shot blasting machine, such as the protective plate, directional sleeve, dividing wheel, blade, impeller, etc., are all CNC precision machined with popular mold steel, with a machining accuracy of ± 0.01mm. It is required to use low-pressure vacuum heat treatment after machining, with a hardness of 58-62HRC, and the best hardness is 60-62HRC, which increases the wear resistance of the components. If the hardness exceeds 62HRC, the components will become brittle and easy to break. After on-site verification, it has been found that the use of steel shot with a diameter of less than 1.5mm (especially steel wire cutting shot, which can easily damage blades due to excessive steel shot) has a service life of more than three times that of cast products for the above vulnerable parts.

　　⑷彈丸循環系統。彈丸循環系統由螺旋輸送器、斗式提升機、丸砂分離器、氣動供丸閘閥、溜丸管等組成。見圖2。圖2 彈丸循環系統拋丸室底部的螺旋輸送器采用縱向和橫向兩種方式，負責將室體底部溜丸斗所收集的彈丸經溜丸槽輸送至斗式提升機，螺旋輸送器的一端軸頭按行業標準配制脈沖輪，可檢測跟蹤螺旋輸送器的工作狀態，一旦出現卡阻等故障，可及時將信號反饋至PLC 進行處理，保證設備的安全運轉。斗式提升機由驅動電機，減速器，主、被動輪，輸送帶，挖砂斗和張緊裝置等組成。提升機的下端進料口接螺旋輸送器，上端出料口接分離器。分離器采用現常用的滿幕簾風選式丸渣分離器。分離效率不低于99%。供丸系統采用SC 型氣缸控制的供丸閘門。吊鉤自轉機構由減速機、主動鏈輪、鏈條、減速機機座等組成，使定位吊鉤上的鏈輪與自轉鏈條相嚙合，保持拋丸過程中工件始終處于旋轉狀態，適當調整減速機機座便可保持自轉鏈條的松緊度。

　　⑷ Bullet circulation system. The pellet circulation system consists of a screw conveyor, bucket elevator, pellet sand separator, pneumatic pellet gate valve, and pellet chute. See Figure 2. The spiral conveyor at the bottom of the shot blasting chamber in Figure 2 adopts two methods: longitudinal and transverse. It is responsible for conveying the pellets collected by the bottom of the chamber through the chute to the bucket elevator. One end of the spiral conveyor shaft is equipped with a pulse wheel according to industry standards, which can detect and track the working status of the spiral conveyor. Once there is a jamming or other fault, the signal can be promptly fed back to the PLC for processing to ensure the safe operation of the equipment. The bucket elevator consists of a drive motor, a reducer, active and passive wheels, a conveyor belt, a sand digging bucket, and a tensioning device. The lower inlet of the elevator is connected to a screw conveyor, and the upper outlet is connected to a separator. The separator adopts the commonly used full curtain air selective pellet separator. The separation efficiency is not less than 99%. The pill supply system adopts SC type cylinder controlled pill supply gate. The hook rotation mechanism consists of a reducer, an active sprocket, a chain, a reducer base, etc., which enables the sprocket on the positioning hook to mesh with the rotation chain, keeping the workpiece in a rotating state during the shot blasting process. Adjusting the reducer base appropriately can maintain the tightness of the rotation chain.

　　⑸除塵系統(脈沖離線清灰)。拋丸器除塵系統采用三級除塵，含塵氣流經除塵管道、慣性沉降室、旋風除塵器、脈沖除塵器、排風機和排風管道排入大氣。慣性除塵器將空氣中的粉塵分離出來，使顆粒較大的粉塵下沉。再經過旋風除塵器，過濾掉大部分的灰塵，這樣就減少了精密除塵器入口處的灰塵濃度，從而達到更好的除塵效果。最后經脈沖濾筒除塵器進行精過濾，達到排放標準(河南省標準是10mg/m3，高于國家標準20mg/m3)，最后通過風機、煙囪排入大氣。

　　⑸ Dust removal system (pulse offline dust cleaning). The shot blasting dust removal system adopts three-level dust removal, and the dust containing gas flows through the dust removal pipeline, inertia settling chamber, cyclone dust collector, pulse dust collector, exhaust fan and exhaust pipeline and is discharged into the atmosphere. Inertial dust collectors separate dust from the air, causing larger particles of dust to sink. After passing through the cyclone dust collector, most of the dust is filtered out, which reduces the dust concentration at the entrance of the precision dust collector and achieves better dust removal effect. Finally, the fine filtration is carried out through a pulse filter cartridge dust collector to meet the emission standards (the standard in Henan Province is 10mg/m3, which is higher than the national standard of 20mg/m3), and finally discharged into the atmosphere through fans and chimneys.

　　⑹電氣控制系統。拋丸設備采用西門子(S7-200SMART)PLC 集中控制控制系統運行，安全可靠，操作靈活，維修方便。系統具有故障實時報警顯示裝置，設備有過載保護裝置，短路保護裝置，整套系統采用了多種控制方法，使調試、維修人員能夠更輕松地對設備進行調整。這時，操作工可按順序依次啟動各功能部件，也可以為了測試各相關部件的性能、運行狀況等而不按順序點動操作單個功能部件(如提升機、拋丸器)。為了保證正常安全運行，設備配有報警裝置，若在生產過程中發現某一運動部位出現故障，就會立即報警，停止全線運行。這套系統主回路主要完成電能的分配和控制，以控制每臺單機電動機為主要目的。主回路各支路由小型高分辨斷路器實現短路保護，由熱繼電器實現過載及缺相保護。控制回路以可編程控制器(PLC)為核心，配以主令開關元件、檢測元件、指示元件及報警單元等，采集和傳輸PLC 所需的各種輸入信號和輸出信號。該裝置具有彈丸循環系統失效報警功能，系統內任意部位失效，為防止彈丸卡殼燒毀電動機，使供丸閘門自動關閉，停止運轉。拋丸器的電流(反映供丸閘的流量)以電流表顯示，同時將此電流值轉換為標準的4 ～20mA 電流信號，傳送給整合在PLC 上的模擬量輸入模組，讓PLC可以實時得知拋丸機若因馬達熱保護、空氣開關未關閉、電氣元件失效或彈丸流量不足而造成流速過小的情形。報警發出，拋丸清運工作禁止進行。

　　Electrical control system. The shot blasting equipment adopts Siemens (S7-200SMART) PLC centralized control system for operation, which is safe, reliable, flexible in operation, and easy to maintain. The system has a real-time fault alarm display device, and the equipment has overload protection device and short circuit protection device. The entire system adopts multiple control methods, making it easier for debugging and maintenance personnel to adjust the equipment. At this point, the operator can start each functional component in sequence, or they can operate individual functional components (such as elevators, shot blasting machines) in a non sequential manner to test the performance, operating conditions, and other related components. In order to ensure normal and safe operation, the equipment is equipped with an alarm device. If a malfunction is found in a moving part during the production process, an alarm will be immediately triggered and the entire line will be stopped. The main circuit of this system mainly completes the distribution and control of electrical energy, with the main purpose of controlling each individual motor. Each branch of the main circuit is equipped with small high-resolution circuit breakers for short-circuit protection, and thermal relays for overload and phase loss protection. The control circuit is centered around a programmable logic controller (PLC), equipped with master switch components, detection components, indicator components, and alarm units, etc., to collect and transmit various input and output signals required by the PLC. The device has a failure alarm function for the projectile circulation system. If any part of the system fails, in order to prevent the projectile from jamming and burning the motor, the supply gate will automatically close and stop running. The current of the shot blasting machine (reflecting the flow rate of the shot blasting gate) is displayed on an ammeter, and this current value is converted into a standard 4-20mA current signal, which is transmitted to the analog input module integrated on the PLC. This allows the PLC to know in real time if the shot blasting machine has a low flow rate due to motor thermal protection, air switch not turned off, electrical component failure, or insufficient shot flow. Alarm issued, shot blasting and cleaning work is prohibited.

　　鍛件拋丸質量提升要素經過常年拋丸設備使用經驗的積累總結出拋丸機主要依靠以下幾個要素提升鍛件表面質量：⑴拋丸室密閉設計杜絕跑鋼丸；⑵根據一次拋丸鍛件總重和數量確定拋丸器選取的數量和位置分布；⑶鋼丸的選取決定鍛件拋丸后表面粗糙度和亮度，推薦使用φ1.2mm 鑄鋼丸效果最佳，如想降低生產成本可使用φ1.5mm 以下鋼絲切丸；⑷除塵設備風量的設計選用應大于理論值15%，保證零件表面無粉塵殘留，保證下道除銹工序效果更佳。

　　After years of experience in using shot blasting equipment, it has been summarized that shot blasting machines mainly rely on the following elements to improve the surface quality of forgings: (1) The closed design of the shot blasting chamber prevents steel shot from escaping; ⑵ Determine the quantity and location distribution of shot blasting equipment based on the total weight and quantity of each shot blasting forging; The selection of steel shot determines the surface roughness and brightness of forged parts after shot blasting. It is recommended to use steel shot with a diameter of 1.2mm for the best effect. If you want to reduce production costs, steel wire cut shot with a diameter of less than 1.5mm can be used; The design and selection of air volume for dust removal equipment should be greater than the theoretical value by 15% to ensure that there is no dust residue on the surface of the parts and that the next rust removal process is more effective.

　　結束語

　　Conclusion

　　本文結合總結數據設計步進式懸掛拋丸機，對被清理鍛件進行表面清理和去氧化皮(鑄態鑄件及正回火后鑄件)，能有效提升熱處理后鍛件表面拋丸質量，提高產品市場競爭力的同時，通過自動化控制降低操作工勞動強度，提升操作人員現場工作安全環境。

　　This article combines summary data to design a step-by-step suspension shot blasting machine, which can effectively improve the surface shot blasting quality of the cleaned forgings (as cast castings and castings after normal tempering), enhance product market competitiveness, and reduce the labor intensity of operators through automatic control, thereby improving the safety environment for on-site work of operators.

　　本文由 自動拋丸機  友情奉獻.更多有關的知識請點擊  http://www.qzxcdz.com/   真誠的態度.為您提供為全面的服務.更多有關的知識我們將會陸續向大家奉獻.敬請期待.

　　This article is a friendly contribution from an automatic shot blasting machine For more related knowledge, please click http://www.qzxcdz.com/ Sincere attitude To provide you with comprehensive services We will gradually contribute more relevant knowledge to everyone Coming soon.

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