Table of Contents

I. Purpose and Features of the Machine----------------------------------

II. Main Structure and Working Principle-----------------------------

III. Main Technical Specifications--------------------------------------

IV. Installation and Adjustment of the Machine---------------------------------

V. Operation and Precautions of the Machine----------------------------

VI. Maintenance and Care of the Machine----------------------------------

VII. Common Fault Causes and Troubleshooting Methods-------------------------

I. Purpose and Features of the Machine

This machine uses a high-speed rotating impeller to throw shot blasts onto workpieces that are continuously tumbling inside a drum, achieving the purpose of cleaning. It is suitable for rust removal, oxide scale removal, and surface strengthening of small castings, forgings, stampings, etc., in various industries, especially for cleaning and strengthening parts that are prone to impact damage.

(Note: This machine cannot clean high-temperature parts or parts with flash burrs, as this may damage the track.)

This machine is a new product developed by integrating domestic and foreign technologies. It is a cleaning equipment with good cleaning effect, compact structure, low noise, and good completeness, featuring the following characteristics:

1. This machine adopts the Q034ZZ centrifugal shot blasting wheel, which has been developed by our company by integrating some new domestic sealing technologies. Over ten years of use has proven that this shot blasting wheel features a long service life, simple structure, and low failure rate.

2. It uses an air-wash separator, providing good separation efficiency and high productivity, which positively contributes to extending the blade life.

3. It employs a bag-type dust collector, with dust emission concentrations below national standards, improving the working environment for operators.

4. It uses wear-resistant rubber tracks, reducing collision and damage to workpieces and lowering machine noise.

5. After workpiece cleaning is completed, the tracks reverse to automatically discharge the workpieces, reducing labor intensity for operators.

II. Main Structure and Working Principle

This machine is a compact cleaning device, mainly consisting of a cleaning chamber, shot blasting wheel assembly, screw conveyor, elevator, separator, shot supply system, electrical system, and dust removal system.

Working Principle: After adding workpieces not exceeding the specified quantity into the cleaning chamber, the machine starts, and the workpieces are driven by the drum to tumble. Meanwhile, the shot blasting wheel throws shot at high speed, forming a shot stream that uniformly impacts the workpiece surfaces, achieving cleaning. The thrown shot and sand pass through holes in the rubber tracks, flow into the bottom steel mesh screen, are conveyed by the screw conveyor into the elevator, and then lifted to the separator for separation. Dust is drawn by the fan into the dust collector for filtration, with clean air discharged into the atmosphere. Dust on the bags falls into the dust collection box at the bottom of the dust collector via mechanical rapping, which users can periodically remove. Waste sand flows out through the waste pipe and can be reused by users. The shot-sand mixture is recovered through the recovery pipe back into the chamber, separated again by the separator, and clean shot enters the shot blasting wheel through the electromagnetic shot gate of the supply system for further blasting of workpieces.

III. Main Technical Specifications

1. Track end disc diameter--------------------------φ650mm

2. Track end disc rotation speed--------------------------3.6r/min

3. Maximum single workpiece weight to be cleaned-----------10kg

4. Maximum drum load capacity (for easily tumbling parts)-----200kg

5. Productivity-----------------------------------600~1200kg/h (gray iron castings)

6. Shot blasting wheel:

          Model---------------------------Q034ZZ

          Rotational speed---------------------------2460r/min

          Impeller diameter---------------------φ394mm

          Shot blasting flow rate------------------------120kg/min

          Shot blasting wheel power------------------7.5kw

7. Dust collector air volume----------------------------2000m³/h

8. Total installed capacity----------------------------12.67kw

9. Machine overall dimensions (L×W×H)------1400×1250×3538mm

10. Total machine weight----------------------------2341.5kg

(Note: Productivity depends on the complexity and surface area of the workpiece. Generally, the cleaned part surface area per minute is ≤0.25m²)

IV. Machine Installation and Adjustment

(I) Machine Installation:

1. Foundation construction shall be carried out according to the foundation drawing. The user shall prepare concrete based on local soil conditions. After checking the horizontal level of the plane with a level, installation can proceed, and all anchor bolts shall be tightened.

2. Before shipment, the cleaning chamber and shot blasting unit have been assembled into one body. During overall installation, as shown in Figure 1, fasten the elevator (Item 2) to the elevator on the cleaning chamber with bolts. When installing the bucket elevator, pay attention to adjusting the upper driving pulley bearing housing to keep it level, preventing belt deviation. Then fasten the separator (Item 1) to the upper part of the elevator with bolts.

3. Install the shot supply gate (Item 3) on the separator, and insert the shot return pipe into the steel pipe at the rear of the cleaning chamber (Item 7). Connect all pipelines according to the dust removal system diagram. The user may prepare a waste bin for handling separated waste materials.

4. See Figure 3 for the installation diagram of the separator. During normal operation of the separator, the shot curtain should have no gaps. If a full curtain cannot be formed, adjust the weight (Item No. 1) until a full curtain is achieved. If the shot and sand separation effect is poor, adjust the separation plates (Item No. 2 and Item No. 3) to obtain a good separation effect. Large materials after shot screening should be removed regularly.

5.

(II) No-load commissioning

1. Before trial operation, you must first familiarize yourself with the relevant provisions in the instruction manual and have a comprehensive understanding of the structure and performance of the equipment.

2. Before starting, check whether all fasteners are loose and whether the lubrication of the machine meets the requirements.

3. The machine requires correct assembly. Before starting, perform a single-action test on each component and motor. The rotation direction of each motor should be correct, and the track and elevator belt should be properly tensioned without deviation.

4. Check the no-load current of each motor, bearing temperature rise, reducer, and shot blasting volume for normal operation. If any issues are found, promptly identify the cause and make adjustments.

5. After confirming that the single-action equipment has no issues, start the dust collector, elevator, drum forward rotation, and shot blasting unit in sequence for a no-load trial operation. The no-load operation time is one hour.

Note: This machine has undergone no-load and load tests at the factory before shipment.

V. Machine operation and precautions

(I) Machine operation:

1. All operators of this machine must have a comprehensive understanding of this manual, as well as the working principle, performance, operation method, and lubrication of the machine before operation.

2. Add shot (200 kg) into the drum gradually, then place the workpiece inside, close the loading door, and prepare to start.

3. Start the dust collector fan.

4. Start the machines in sequence: hoist, screw conveyor, drum forward rotation, shot blasting machine, and shot supply gate to begin the cleaning process. After cleaning is complete, shut down in sequence: shot supply gate, shot blasting machine, drum forward rotation, screw conveyor, hoist, and dust collector fan. Then start the rapping motor for dust removal, which stops after a certain period;

5. After the shot blasting machine has completely stopped, open the loading door and press the drum reverse rotation button to automatically discharge the material;

6. In an emergency, press the emergency stop button to immediately halt all machine operations;

7. After all work is completed, promptly turn off the dust collector;

8. The ventilation and dust removal system is equipped with butterfly valves. Adjust the two butterfly valves as needed to achieve good separation efficiency;

9. Adjustment of the directional sleeve of the shot blasting machine:

    The adjustment of the directional sleeve can be performed as shown in Figure 5. During use, wear of the directional sleeve increases the shot spread angle, accelerating wear of the shot blasting machine and other protective plates in the cleaning chamber. Therefore, when the wear of the directional sleeve exceeds 10 mm, it should be replaced with a new one (the angle between the opening direction and the horizontal line is 45°).

                        Figure 5: Schematic diagram of directional sleeve adjustment

(II) Precautions:

1. Regularly remove dust from the dust collection box below the dust collector to prevent blockage of the dust discharge pipe and ensure effective dust removal;

2. Frequently clean debris from the bottom of the cleaning chamber and the screen under the separator funnel;

3. Regularly sweep up shot around the equipment to prevent slipping and injury;

4. Frequently check the tracks in the cleaning chamber and the hoist belt for any deviation to avoid belt damage;

5. Do not open the loading door until the shot blasting machine has completely stopped to prevent accidents.

VI. Machine Maintenance and Care

1. After each work shift, the machine should be cleaned thoroughly.

2. Regularly inspect the wear condition of the protective plates in the cleaning chamber and the wear-resistant parts such as the directional sleeve and impeller wheel in the shot blasting machine. Replace them immediately if severely worn.

3. Lubricate regularly as specified, and frequently check whether the machine operates smoothly. Refer to Figure 6 and Table 2 for lubrication points.

4. Periodically inspect all transmission parts, clean components, and replace worn parts.

5. When inspecting or repairing the machine, the power must be disconnected to prevent accidents.

6. The protective plates in the cleaning chamber can be replaced periodically based on wear condition. When replacing, control the installation gap between plates to within 1.5 mm. Refer to Figure 7 for replacement.

Note: The motor of the shot blasting machine track transmission system on the upper part of the elevator should be lubricated according to the motor lubrication requirements.

VII. Common Fault Causes and Troubleshooting Methods