The Chinese engine plant BMW Brilliance Automotive (BBA) is characterized by state-of-the-art production.
The blasting system tailored for this purpose was perfectly integrated into the production line and offers an optimal blasting result in the shortest possible processing time.
Batch size 1, no set-up times, unmanned production, reliable blasting results and the integration into the existing production line were the main focus when planning the new blasting system for BMW Brilliance Automotive in Shenyang, China. The automobile manufacturer’s most modern engine plant in the world is located here.
In close cooperation with the BMW project managers, the Pangborn Group developed a tailor-made concept that meets all the needs of a state-of-the-art production line. The heart of the scope of delivery is a TCH (turn chamber hook) system suitable for foundries and forges, which is solid, low-maintenance and fully automated for intensive three-shift operation. The overall armor of the facility is 23 to 25 millimeters thick and consists of manganese and cast chrome.
Four frequency-controlled High-performance turbines (double disc wheel) with 22 kW installed power each ensure an optimal radiation result in the shortest possible processing time. The new type of separation system for coarse particles of any kind that could fall off the workpieces was also introduced.
Using modern measuring technology, the space available in the existing production hall was recorded and the design of the entire scope of delivery was based on this. The introduction of the components sometimes required precision work; even an argon pipeline as strong as an arm had to be re-laid.
Loading and unloading parallel to the blasting process
The seven different crankcase types (3- and 4-cylinder) are transported every 40 seconds.
units for the blasting machine. There they are removed by a robot using a gripper system and turned by 180 ° and transferred to the loading robot of the blasting system. In order to reduce the overall cycle time, each robot has two gripper units, which, through their way of working, significantly reduce the number and speed of the robot travel paths.
The loading robot positions the different workpiece types in the correct position in the two workpiece holders of the blasting system, whereby the data matrix code on the workpieces is safely and permanently protected. This contains all the important information about the company’s internal material and quality tracking and must not be damaged.
The turning chamber principle of the system enables a very short cycle time, since the loading and unloading of the system runs parallel to the blasting process. An individual blasting program can be assigned to each component type, which is safely implemented even when two different workpiece types are loaded in the blasting system.
After processing the part-specific blasting parameters, the workpieces are removed and residual blasting media and dust are cleaned using robotics and vibrating stations. The emptying robot rotates the component around its own axis and can also position oil and water channels that are difficult to clean in a targeted manner. The two heavy-duty jogging and rotating units then pick up the parts with a positive and non-positive fit and remove even the smallest particles from the interior of the engine blocks.
The separated beam tel is fed back to the blasting system by means of a conveyor screw. The blasted parts are transported to the further processing steps on the individual workpiece carrier.
Complete documentation
The system control constantly monitors that all parts that are fed to the next work step have been processed in the required quality. If deviations are noticed here, the discharge for re-inspection or post-processing takes place. For permanent quality assurance, all blasting parameters are assigned to the workpiece and documented in the operating data acquisition system. The evaluation software integrates perfectly into the Industry 4.0 concept of the overall production.
The modular principle of the blasting system enables the simple and inexpensive adaptation of the entire system to new workpieces and blasting tasks.
Contact / Arrange Consulation
V + S Vogel & Schemmann Maschinen GmbH – Hagen
Philipp Söhnlein, Head of Sales
Germany@pangborn.com
www.pangborn.com
With friendly support from:
www.springerprofessional.de
