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Rösler Shot Blast Technology Highly Successful

Rösler Oberflächentechnik GmbH has been steadily improving its already excellent market position in the area of custom-built systems

At the same time, the Rösler group of companies has established itself successfully in the field of commercial shot blast systems and increased its market penetration. It is in the aviation industry, as well as in the fields of die-casting and forging shops, that Rösler’s innovative, individual and economical surface technologies have been contributing to improved product quality and a more cost-effective production flow. With the acquisition of Köhne Lackieranlagen GmbH, Rösler is now a single-vendor source of complete preservation lines.

Europe's largest overhead rail shot blast system

Shot Blast Technology for Offshore Wind Power

Iron foundry GGT- Großguss Torgelow GmbH is one of several manufacturers of components used in wind power generation systems. The company has invested in a new casting production line, specially designed to produce oversized cast components for offshore wind turbines. For GGT’s new production line, Rösler has developed a massive shot blast system to clean and remove residual casting sand from these components.

With about 16,500 onshore wind turbines and an output of nearly 16.5 gigawatt hours, Germany is the world’s top generator of wind power. In addition, the German wind power industry is rapidly expanding seaward. On German coasts, up to 25 gigawatt (GW) hours of wind power is planned to be generated by offshore systems by 2030. Wind power is a growth industry throughout Europe. The German Institute for Wind Energy forecasts that by 2008, 36 GW hours of wind power will be available in Europe. Today, German wind energy system and component manufacturers generate a higher proportion of the net product abroad than at home.

A new casting production line

GGT-Großguss Torgelow GmbH belongs to the group of manufacturers that produce components for the construction of wind turbines, as well as machine- and heavy equipment building and engine casting. Components such as rotor hubs and base frames with high stress load must be cast to the highest quality specifications. The process developed for this purpose by the iron foundry industry not only offers uniform quality results, but cuts costs as well. This contributes to an increase in both the performance potential of the system's manufacturers, and the reliability and cost-effectiveness of the wind turbine systems, which is very important for offshore use. Offshore systems are significantly larger than land-based systems. Their larger size requires a corresponding increase in the production volume of rotor hubs and gear components.
42-meter overhead rail shot blast system

A Rösler continuous-flow overhead rail shot blast system was required to clean the cast components, up to 8 m (26 ft) in length and weighing up to 100 tons, and to remove residual casting sand. This shot blast system is an integral part of the new production facility for oversized cast parts. The shot blast system was planned correspondingly big and powerful-it is the only overhead rail system of its size in Europe. The total system, including loading and unloading stations, measures 42 m (138 ft) in length, including an 18 m (59 ft) long shot blast cabin. Different sizes and shapes of components can be treated. This was the decisive factor for Rösler. In order to ensure an economical continuous feed of the heavy parts, a tandem operation with two parallel-running, automatically controlled, cranes was developed. Within the shot blast zone, there are three fixed crane positions. A total of ten high-performance blast wheels operate at different angles to deliver highly efficient cleaning. The entire shot blast system is designed to withstand very extreme production conditions. The cabin is constructed of 8 mm (1/3 in) manganese steel and 12 mm (1/2 in) manganese plates. The maximum noise level of the system is below 80 dB.
As an all-round supplier, Rösler GmbH is an international market leader in the production of surface finishing, shot blasting machines, painting systems and preservation lines as well as process technology for the rational surface finishing of metals and other components. Besides the German plants in Memmelsdorf and Hausen, the Rösler Group has branches in Great Britain, France, Italy, The Netherlands, Belgium, Austria, Switzerland, Spain, Brazil, South Africa and USA.

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