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Rösler: A disk spring every 10 seconds

ZF Sachs, one of the world's leading manufacturers of drive and chassis components is involved in a joint venture with a Chinese supplier, and needed a partner in shot blast technology. They brought their requirements to Rösler Oberflächentechnik and Rösler engineers developed a continuous-flow system to shot peen disk springs.

Performance specifications for shot blast systems often provide information gained from detailed tests carried out in order to prove the functioning of a work process, and how to treat the most unique geometries.  In Shanghai, performance specifications were used to select the RBD 600-2 continuous-flow system to peen disk springs.  According to the Almen measuring method, deflection values between 0.1 and 0.25 mm (equivalent to a shot blast intensity of 4 to 10 A) as well as a 98% degree of overlap, were to be achieved by the system.

The pre-defined dimensions for the disk springs in this application range from 110 mm (4 in) to 300 mm (13 in) in diameter.  Another objective for the system was that it be fully automated.

In order to meet these specifications, a system concept incorporating two parts conveyors (each with a working width of 300 mm (13 in)) was developed, where one of the conveyors transports the disk springs continuously underneath four blast wheels.   These are arranged at an angle facing towards one another to achieve an even shot blast result.  After the springs have been shot blasted on one side, they are conveyed to a turning station, where they are automatically rotated by 180º and conveyed back to the blast wheels by the conveyor running parallel in the opposite direction.

In order to achieve optimum contact on parts of different dimensions and geometries, as well as to prevent the parts from being blown out of shape, it was necessary to equip the conveyors with different component guide rails.  In addition, two component recognition systems ensure the pass-through process runs smoothly.

The required cycle time of 10 seconds per spring was realized easily and consistently with this system. The system is operated in two shifts, resulting in an output of 1.5 million disk springs annually. 

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 Untermerzbach and Bad Staffelstein, the Rösler Group has branches in Great Britain, France, Italy, The Netherlands, Belgium, Austria, Switzerland, Spain, China, Brazil, South Africa and USA.

 

RBD system shot peens 1.5 million disk springs a year
Two parts conveyors ensure the springs are shot blasted on both sides


www.rosler.com

 

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