Mass Finishing System

Vibratory Finishing Machine vailable in bowl volumes ranging from 30 to 1000 litres. The bowls are rubber or polyurethane lined for durability. Parts, media and compound are placed in the machine for processing. In the forward mode, the machine runs counter-clockwise and parts are processed.

"A" ... Rotary Vibrators
       The A - range of rotary vibrators with  their powerful MS/E-V magnetic  separators is in a class of its own. This machine type was specially  designed for processing of parts that can be separated magnetically. The electrical controls are designed to allow the finishing process to run fully automatic.
 

Features:
        ► Work bowl re-enforced with extra gussets  and equipped with special ramp in the process channel for easy magnetic separation. High performance magnetic separation, type MS/E-V.
        ► Rosler double-flange vibratory motor with 2 speeds (1500 and 1000 rpm at 50 Hz); easy and safe lubrication of the bearings 
        ► Adjustable imbalance weights allow different grinding intensities 
        ► Wear resistant lining made from hot poured polyurethane
        ► Media unload plug with integrated effluent drain
        ► Flexible desing of control panels and compound dosing systems
Extras:
        ► Variable speed of vibratory motor
        ► Extra bottom drains
        ► Undersize media classification: Integrated into media unload plug
        ► Noies protection equipment "A"... HS high speed vibratorsProcess bowl:
        ► Made with specially treated steel
        ► Special gusseting for extra strength
        ► Wear resistant, double-thick lining made from hot poured polyurethane Machine base
        ► Re-enforced wlding fabrication Drive system:
        ► Special high performance Rosler vibratory motor Power +
        ► Amplitude up to app. 10 mm 
        ► Variable motor speed*
        ► Central lubrication 
* especially useful during the seporation processIMPORTANT when utilizing

magnetic separation:
    Almost all finished steel parts require de-magnetization prior to further treatment We offer the following options:
    ► Plate de-magnetization: Installed in the magnetic belt separators of the types MS/E-V and MS/E
    ► Drum magnet separators: Optionally equipped with basic de-magnetization unit
    ► Special solutions: De-magnetization tunnels and  conveyor belts with single or double de-magnetizing plates

 

IMPORTANT when utilizing
magnetic separation:
       Almost all finished steel parts require de-magnetization prior to further treatment
We offer the following options:
       ► Plate de-magnetization: Installed  in the magnetic belt separators of  the types MS/E-V and MS/E
       ► Drum magnet separators: Optionally equipped with basic de-magnetization unit
       ► Special solutions:De-magnetization tunnels and conveyor belts with single or double de-magnetizing plates

Type:           R 780 A R 1050 A R 1050 A-HS
Process bowl                
Total volume     780 1050 1050
External diameter max. mm A 1805 1805 1805
Process bowl width mm B 435 465 465
Overall length of processing channel mm C 4100 4100 4100
Machine Height mm D 1275 1375 1375
Unload height mm E 1045 1105 1105
Height media unload plug mm F 600 550 550
Total length incl. mognetic separator mm K 3000 3000 3000
Lining                
Hot PUR thickness in work bowl bottom mm   20 25 50
                 
Separation     Mognetic separal. Mognetic separal. Mognetic separal.
                 
Drive power                
Speed (at 50 Hz) * RPM   1500 1500 1500
Connected load * Kw   7,5 7,5 Power* 12,5
                 
Medig unload nlua Ø mm   190 190 190

 

"R"… Rotary Vibrators

Flat bottom rotary vibrators are perfect for treatin large and bulky as well as delicate parts. The flat bottom ensures a perfect immersion of the parts into the media mass. For parts that need to be processed individually without touching each other, so-called "paddle wheels" with dividers are available which create separate processing chambers in the the work bowl. Finished parts are usually taken out manually. Bottom unload gates allow complete evacuation of the work bowl and external separation of media from parts (option).  

     

      

Technical details:

► Flat bottom processing channel

► Reversing of rotational direction of vibratory motor moves the parts to the top of the media mass for easy manual removal

► Rosler double-flange vibratory motor with 2 speeds (1500 and 1000 rpm at 50 Hz); easy and safe lubrication of the bearings

► Adjustable imbalance weights allow diferent grinding intensities

► Wear resistant lining mode from hot poured polyurethane

► Media unload plug with integrated effluent drain

► Flexible desing of control panels and compound dosing systems

Extras:

► Variable speed of vibratory motor

► Extra bottom drains

► Undersize media classification: Integrated into media unlod plug

► Noise protection equipment

► Bottom unload gate for complete unload of the work bowl

► Reversing imbalance weights

Multi-Power package:

Two levels of vibratory intensity (amplitude) can be automatically selected for aggressive de-burring followed by gentle smoothing

 

"R"… HS high

speed vibrators Process bowl:

► Made with specially treated steel

► Special gusseting for extra strength

► Wear resistant, double-thick lining mode form hot poured polyurethane Machine base

► Re-enforced welding fabrication

Drive system:

► Special high performance Rosler vibratory motor Power

► Amplitude up to app. 10 mm

► Variable motor speed*

► Central lubrivation

"R"… KP special ball

bumishing systems

For extra heavy loads:

Specially designed for ball burnishing or high-pressure de-burring with steel/stainless steel media.

► High power vibratory drive system

► Re-enforced coil springs

► Work bowl re-enforced with extra gussets

► Rubber lining of work bowl Recommended accessories:

► Suction pump and splash guard

 

Type:           R 125 R 220 R 320 R420 R 620 R 780
            R 125 R125 KP   R 320 R 320 KP R 320 HS   R 620 R 620 KP R 620 HS R 780 R 780 HS
Process bowl                                  
Total volume     125 125 220 320 320 320 420 620 620 620 780 780
External diometer max. mm A 910 910 1190 1350 1350 1350 1520 1695 1695 1695 1805 1805
Process bowl width mm B 210 210 250 330 335 305 360 430 430 430 395 435
Overall length of processing channel mm C 1950 1950 2600 2840 2840 2840 3250 3510 3510 3510 3750 3750
Mcahine Height mm D 1010 1010 1070 1070 1110 1110 1235 1200 1200 1280 1225 1225
Height media unload plug mm F 630 620 645 595 630 630 705 625 625 705 600 600
Lining                                  
Hot PUR thickness in work bowl bottom mm   10 10 16 16 16 30 16 20 20 30 20 40
Drive power                                  
Speed (at 50 Hz)* RPM   1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500
Connected load kW   0,75 0,75 3 3 7,5 7,5 7,5 7,5 7,5 Power 12,5 7,5 Power 12,5

* specially useful during the separation proceses

Double batch and triple batch systems - Fully automatic rotary vibrators

The finishing process and parts separation take place simultaneously

The surface finishing of mass-produced parts poses special engineering challenges. For example where no mixing of batches of different parts ("batch integrity"), carryout of media, or media lodging in the parts is allowed. Among other things this requires a reliable and effective undersize media classifiaction system.

Benefits of multi batch systems:

Double and triple bathc systems offer maximum use of available processing capacity by simultaneous surface finishing and separation:

► Fully automatic separation process

► No mixing of parts from different batches. ►

Precise and controlled parts transfer ot the separation unit ensures effective screening. This is a prerequisite for post treatment steps like parts washing and drying

► Can be easily adapted to the most difficult separation tasks

► Excellent separation performance

► Built-in media undersize classification

► Parts can be spray-washed during separation

1 Rotary vibrator:

► Work bowl geometry based on "R" range with special gusseting for extra strength, flat bottom process channel and designed for complete unload.

► Media/parts unload gate, either pneumatically or hydraulically activated

► Rinse station to flush out residual media and parts from the work bowl

► Variable speed for the vibratory motor

► Operator platform Extras:

► "R"… rotary vibrator E-PUR version - Triangular wedge on outside wall of processing channel

Automatic separation technology:

2 Intermediate hopper (holds one complete batch of finished parts and media):

► Variable speed of the vibratory system and variable inclination levels allow exact do- sing of parts and media to the separation unit for optimum separation. Extras: Anti-adhesion package: Prevents finshed parts from sticking to the walls of the

3 Vibratory separation unit with large screen area:

Three screen decks with tumbling steps; screens can be easily replaced without requiring any tools

► Many screen desings available

► Rinse station over screen decks for cleaning of the finished parts

► Adjustable vibration intensity, optionally with speed control Extras: Magnetic Magnet or belt magnetic separator with de-magnetizing system

4 Undersize media classification:

► Special screen deck with slide-in undersize media collecting tray 5 Media return into the work bowl:

► Special loading system for returning media to the work bowl; can also be used for loading raw parts into the work bowl

► Rinse station in loading unit for flushing out media and/or parts from the walls

► Vibratory cross conveyor for transferring the media from the separation to the

Multi-Power package:

Two levels of vibratory intensity (amplitude) can be automatically selected for aggressive de-buring followed by gentle smoothing Special HS high speed version available in model size R 620

Extras:

► Weighing system for automatic media top-up into the woke bowl

► Safety ("police") magnet over media cross conveyor

► Anti-adhesion package: The checket plate pattern prevents finished parts and media from sticking to the walls of loading system.

► Loading hopper equipped with pneumatic flap for gentle loading of media and raw parts into the work bowl 6 Easy-to-operate electrical controls: Fully automatic operation with PLC

► Easy-to-handle operation panel

► Multiple processing programs possible (up 99)

► Clear text display for malfunctions

► Speed control for the various drive units

► MPI interface for integration into a multi-machine environment Extras:

► Recording of operating parameters and machine sttings

► Remote trouble shooting via modem

 

The 2-batch system:

► There are two batches of parts and media in the system: While one batch of parts is processed, a second batch is being separated, a second batch is being separated. This minimizes nonproguctive, idle equipment time.

► The 2-batch system features a processing unit and a stand-alone separation station.

Equipment safety/noise protection

► Safety fence

► Sliding doors minimize the required floor space

The 3-batch system:

► There are three batches of parts and media in the system: While two batches of parts are processed, a third batch is being esparated.

► The 3-batch system features a tandem installation (2 processing units) and one stand-alone separation station. This separation station is used by both processing units for separation of finished parts from media. Non-productive, idle equipment time is minimzed.

extras:

► Combined safety/noise protection cabin reduces the noise level to <80 dB(A)

 

 

7 Compound dosing:

► PLC controlled process water supply system with flow regulator, optionally for fresh water or recycling operation

► Independent control of individual rinse stations

► Dosing pump for precise dosing of compound

 

Type:         R 420 2 CH R620 2 CH R 420 3 CH R 620 3 CH
Dimensions                
Length mm 5300 4400 5300 5400
Width mm 3900 4000 4900 5000
single processing bowl                
Total volume   420 620 420 620
External diameter max. mm 1520 1700 1520 1700
Process bowl width mm 350 430 350 430
Overall length of processing channel mm 3250 3510 3250 3510
Lining                
Hot PUR thichness in work bowl bottom mm 16 20 16 20
Drive power                
Speed (at 50 Hz)* RPM 1500 1500 1500 1500
Connected load kW 7,5 7,5 7,5 7,5

Special Long Radius vibrators type R…/2LR

       With their extra long processing channel Long Radius vibratory systems can be used for batch as well as contimuous feed surface finishing. The work bowl has a double curved wall processing channel with equal channel width and depth. This guarantees excellent rotary movement and immersion of the parts into the media mass.

 

 

 

Technical details:

► Spiral bottom process channel with continuous incline for easy separation

► Double curved walls of processing channel

► Gentle, adjustable "cascade" drop bebind separation ramp.

► Manually insertable separation gate or pneumatically cativated separation flap

► Linear screen area with easy to change separation screen

► Adjustable imbalance weights allow different grinding intensities

► Wear resistant lining made from HD 90 polyrethane

► Media unload plug with integrated effluent drain

► Flexible desing of electrical controls and compound dosing systems Extra bottom drains

Extras:

► Undersize media classification segment integrated into separation screen

► Special separation unit with independent vibratory drive

► Parts load chute

► varivble speed of vibratory motor

Applications:

Continuous feed mode:

► Gentle de-burring and radiusing of delicate parts

► Cleaning

Batch mode:

► Intensive grinding/do-burring/ rodiusing

► ROSLER Keramo-Finish® / REM Isotropic Superfinish ISF® 

 

 

 

 

             

 

 

Technical details:

Parts loading:

Load chute for feeding parts in continuous feed operation Separation of media from finished parts:

Easy to chane screens requiring no tools allow quick ex-change of sepa- ration screens.

Option:

Integrated rinse station over screening area for spray rinsing of the finished parts Long Radius- KP ball burnishing systems For extra heavy loads:

Specially designed for ball burnishing or high- pressure deburring with steel/stainless steel media:

► Re-enforced coil springs

► Lining of work bowl: sprayed polyurethane

► Recommended accessories: Suction pump and splash guard

 

Continuous of batch operation:

Separation package with automatic control of separation flap

 

Type:           R 480/2 LR R 780/2 LR
Process bowl              
Total volume     350 680
External diameter max. mm A 1900 2345
Process bowl width mm B 270 380
Workpiece loading width mm B1 185 250
Overall length of processing channel mm C 5350 6100
Mochine height mm D 1200 1460
Unload height mm E 1030 1060
Screen width mm F 255 405
Lining              
Sprayed PUR thickness in work bowl bot. mm   20 20
Antriebsleistung              
Speed (at 50 Hz)* RPM   1500 1500
Connected load kW   7,5 7,5
               
Media unload plug Ø mm   200 200

Separation technology

To be truly successful, vibratory finishing applications require sophisticated separation technologies. Afier the finishing process the parts must be completely separated from the media. Screen separation is the most commonly used separation technology. Pre-condition: Optimum difference in media and parts size. Small to mid-size ferritic parts can be separated with magnetic separators.

 

 

 

Reverse separation screens:

For some finishing applicltions the media may be bigger than the parts. This requires reverse separation screens for separation of finished parts and media

 

 

Special separation methods:

 

Special separation task:

Linear separation unit with independent vibratory drive Delicate parts can be separated fram the media by using external screening units with independent vibratory frive.

Technical details:

► Drive system either by vibratory motor or magnetic oscillator; both with variable speed

► Special separation screens to ensure optimum discharge of the finished parts

►Separation screens with Built-in tumbling steps Removes media from cup shaped parts

►Special separation flap,   inserted from the top

 

Undersize media classification:

      The media changes its shape and size during the finishing process. Depending on the parts shape this can cause lodging of undersize media in bore holes, blind holes, undercuts, etc. To prevent such lodging, undersize media must be temoved from the finishing system.

       Permaanent undersize media classification: The classification and discharege of undersize media is performed continuously while the vibratory finishing system is running (prpcessing and separation stage).

        Periodic undersize media is only removed The undersize media is only removed during the actual separation step; usually by a screen segment built into the separation screen.

Effluent drain:

Effective removal of effluent from the work bowl is a pre-requisite for a stable finishing process.

 

 

 

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