Export To Vietnam Five Stations Shot Blasting Peening Machine With Dry Dust Collector,Model:MZ-5ST300-P380/2/22 Is Used For Gear Surface Strengthening

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1.Five Stations Shot Blasting Peening Machine With Dry Dust Collector,Model:MZ-5ST300-P380/2/22

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It Is Used For Gear Surface Strengthening.

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Five Stations Shot Blasting Peening Machine With Dry Dust Collector,Model:MZ-5ST300-P380/2/22 Is Used For Gear Surface Strengthening

Equipment Technical Agreement

1.Technical Agreement Overview

This technical agreement is designed by MIZHI Company for shot peening of disc gear and shaft parts. The equipment structure is reasonable, easy to operate, with low noise, fast response speed of all moving mechanisms, and high reliability. It incorporates advanced foreign design and manufacturing concepts, facilitating maintenance and operation. The equipment also features excellent safety performance, being environmentally friendly and non-hazardous to human health.

1.1. Steel Shot Circulation Process

Steel shot from the storage hopper is propelled by the shot blasting wheel onto the workpiece surface. After impacting the surface to achieve the peening effect, the shot falls to the bottom of the shot blasting chamber. A feeding screw transports the shot to the elevator, which then lifts it to the separator. After separation, qualified shot returns to the hopper. A bypass shot pipeline from the hopper to a vibrating screen ensures that only qualified shot enters the feeding screw. When the hopper is low on shot, an automatic feeding system replenishes the entire cycle. Dusty gases in the shot blasting chamber are filtered by a dry dust collector, with the cleaned air discharged into the atmosphere.

1.2. Scheme Design Standards

(1)GB12348-90: Industrial Enterprise Boundary Noise Standard

(2)GB16297-1996: Comprehensive Emission Standard for Air Pollutants

(3)GB/T23576-2009: General Technical Conditions for Shot Peening Machines

(4)ASTM E11: International Sieve Aperture Standard

(5)SAE J442: International Standard for Shot Peening Process Tools

(6)SAE AMS 2430: International Standard for Automated Shot Peening

1.3. Process Parameters

(1) Workpiece Type: Transmission gears, shafts.

(2) Workpiece Size: Maximum diameter × height: φ300×400mm (effective working area).

(3) Steel Shot Type: 0.3～0.6mm wire cut shot, G2 roundness, 58-62HRC.

(4) For arc tooth bevel gears, focus on root arc height: Almen arc height test coupons 0.38mmA～0.50mmA.

(5) Cycle Time: 200% coverage, single string cycle time within 45-60 seconds.

(6) Residual Compressive Stress after Peening: ≤-500MPa at 0.02mm below the tooth root, ≤-950MPa at 0.02-0.06mm below the tooth root.

(7) Surface Quality after Shot Peening: Parts free of rust, oil, and oxide scale, with a grayish-white color.

(8) Shot Peening Method: Gears are peened one string at a time.

Product Process Requirements

1.4 Scope of Supply

One Year's Spare Parts List

2. Machine Features

(1) The body is made of full manganese steel, with a shell life of 10 years, greatly improving maintainability and preventing steel shot leakage.

(2) The feeding screw and elevator recovery system accommodate steel shot sizes of 0.4-1.2mm.

(3) A three-level steel shot separation system:

l Primary pneumatic separation system: Separates broken steel shot of 0.1-0.2mm and dust.

l Secondary cyclone separation system: Separates broken steel shot of 0.05-0.1mm and dust, achieving gas-solid-liquid separation and reducing dust collector load.

l Tertiary vibrating screen bypass filtration system: Screens out broken steel shot according to shot peening requirements.

(4) The vibrating screen adopts a quick-connect design for easy replacement and maintenance. The equipment includes 1 set of vibrating screens.

(5) The human-machine interface features a 12-inch touch screen with 3D animation guidance, offering a user-friendly and powerful interface.

(6) The safety reminder points, maintenance reminder points and operation specification reminder points of the equipment are all beautifully labeled, making them clear at a glance.

(7) All motors are directly driven without belts or chains, greatly enhancing both safety and maintenance performance.

(8) Complies with the SAE AMS2430 international standard for automated shot peening.

(9) The maintenance platform is designed for user convenience.

(10) Equipment noise: ≤82dba within 1 meter around the equipment.

(11) The equipment connects to a dry dust collector with a airflow≥4000m³ and dust emission≤20mg/m³.

3. Detailed Equipment Configuration Description

3.1 Shot Blasting Chamber

1)The chamber is made of 6mm thick Mn13 full manganese steel, ensuring sufficient strength and rigidity.

2)The interior is lined with 10mm thick high-wear-resistant manganese steel plates.

3)The protective plates are connected with wear-resistant cast nuts to protect the bolt heads and facilitate replacement.

4)A maintenance door is located at the rear of the chamber for easy inspection and maintenance.

5)Three protective plates are installed at the top of the chamber for easy removal and internal maintenance.

6)The operating area uses a double-cylinder door drive sealing system for safe operation.

7)he loading and unloading operation area is 1000mm high, designed for Asian ergonomics.

3.2 Rotary Table System

1) Composed of one main rotary table and five planetary rotary tables. The main table rotates stepwise under operator control, moving one table into and out of the shot blasting area with each step.

2) The main rotary table has a diameter of 1350mm.

3) Driven by a speed-reduction motor, the drive mechanism is located outside the shot blasting chamber at the bottom of the equipment for safety and ease of maintenance.

4) The five workstations are designed as five separate compartments to prevent steel shot leakage.

5) Each planetary rotary table has a pulley below it, sharing one drive mechanism. When a planetary table enters the shot blasting area, it engages with the drive mechanism and rotates automatically. When it moves to the loading/unloading area, it disengages and stops, facilitating material handling.

6) The planetary rotary table features a belt automatic disengagement alarm function. If the belt disengages and the table stops, an automatic alarm is triggered.

3.3 Shot Recovery System

3.3.1 Elevator System

(1) The elevator lifts steel shot recovered by the feeding screw to the separator above the shot blasting chamber.

(2) The elevator casing is made of precision-welded steel plates, designed for sectional disassembly. Upper and lower pulley hubs are installed, with a wear-resistant belt and numerous buckets between them. As the belt turns, the buckets transport steel shot from the bottom to the top of the elevator.

(3) The upper pulley hub is movable for belt tension adjustment.

(4) A rotation detection device at the bottom of the elevator triggers an emergency stop and fault alarm if the elevator stops due to a malfunction.

(5) A speed-reduction motor at the top of the elevator drives the belt.

(6) Manganese steel plates are installed at the top of the elevator to reduce wear.

(7) A maintenance door is located in the middle of the elevator for belt inspection, adjustment, or bucket replacement.

3.3.2 Feeding Screw System

(1) One feeding screw is located at the bottom of the shot blasting chamber, collecting and pushing fallen steel shot to the bottom of the elevator.

(2) The screw blade is made of 6mm thick steel plate.

(3) A high-performance speed-reduction motor drives the feeding screw.

(4) The feeding screw is equipped with a working monitoring sensor, triggering a shutdown alarm if abnormal rotation occurs.

3.4 Shot Separation System

The equipment features a three-level separation system: separator, cyclone separator, and vibrating screen, ensuring the steel shot meets AMS-2431 standards after sieving.

3.4.1 Separator

(1) A pneumatic separator powered by a fan to create negative pressure.

(2) The welded structure includes multiple chambers for air flow guidance. The front is a removable maintenance door for daily inspection.

(3) Multi-pole baffle structure, adjustable. It is used to adjust the uniformity of the lower sand curtain.

(4) The shot materials recovered by the screw elevator form a thin and uniform curtain in the separator. High-pressure air passes through this curtain to separate qualified shot materials, crushed shot materials and dust. Qualified shot materials enter the silo for circulation, unqualified broken shot materials enter the waste hopper, and dust enters the dust collector.

3.4.2 Cyclone Separator

(1) The cyclone separator recovers broken shot and separates dust, sending fine dust to the dust collection system.

(2) Located before the dust collector, it separates broken shot and dust.

(3) Broken shot enters the cyclone separator's outer cylinder tangentially, accelerates and spirals downward between the inner and outer cylinders. Wind speed decreases as it passes through the inner cylinder, causing broken shot to settle while fine dust is carried into the dust collection pipe and finally into the dust collector.

3.4.3 Vibrating Screen System

(1) The vibrating screen is located below the elevator and operates in a bypass filtration mode.

(2) When the recovery system is activated, the vibrating screen works simultaneously, filtering approximately 40kg/min of steel shot to ensure non-conforming broken shot is expelled from the machine.

(3) The feed port is equipped with a manual shut-off valve for maintenance convenience.

(4) The vibrating screen has a diameter of 600mm and uses a single 40-mesh screen (screen aperture lower limit: ≤0.35mm). The screen mesh can be selected and replaced according to the shot type and is designed for quick connection and easy removal.

3.5 Shot Storage System

3.5.1 Storage Hopper

(1) Each storage hopper can hold 1.5 tons of steel shot.

(2) Each outlet of the hopper is fitted with a manual slide valve for maintenance use.

(3) A glass observation window on the side of the hopper allows visual inspection of the shot level.

(4) The hopper is equipped with an alarm system that triggers an automatic feeding prompt when the steel shot level falls below a certain threshold.

3.5.2 Automatic Feeding Device

(1) Located on the side of the shot blasting chamber, the outlet is fitted with a pneumatic butterfly valve.

(2) Upon receiving a low-level signal from the hopper's sensor, the pneumatic butterfly valve opens, and the system automatically compensates by adding shot. This achieves closed-loop control of the shot supply.

(3) The automatic feeding device itself has a material level sensor that triggers an alarm on the touch screen when shot is lacking.

3.6 Shot Blasting Wheel

3.6.1 P380-22KW Shot Blasting Head

(1) Two shot blasting heads are vertically arranged on the rear side of the shot blasting chamber. The motor brand is ABB, model P380.

(2) Features one impeller, eight mold steel wear-resistant blades (direct plug-in type), a directional sleeve, and a shot distributor, which control the shot direction and pre-accelerate the shot.

(3) The wear-prone parts of the blasting head are made of high-wear-resistant materials with attached wear-resistant steel plates for easy replacement.

(4) All parts are manufactured using full machining technology and low-pressure vacuum heat treatment, ensuring stable performance, long service life of spare parts, compact size, and easy maintenance.

(5) Custom ABB motors are used, which have an enlarged balance tolerance range to prevent motor damage caused by uneven wear of the eight blades.

(6) Technical Specifications:

l Quantity: 2 Sets

l Model: P380

l Impeller Diameter: 380mm

l Blades: 8 Pieces

l Impeller: Double-Disc Venturi Sealing Technology

l Shot Velocity: 60～90 m/s (variable frequency speed regulation, effective peening height 350mm)

l Motor Power: 22kw/Direct-Drive/ABB Dedicated Motor for Shot Blasting Head

l Maximum Shot Sand Flow: 2*300kg/min

l Motor Speed: 1500-3000RPM Adjustable

l Abnormal Motor Speed Alarm for Shot Blasting Head

l Frequency Conversion Drive (Enables Adjustable Peening Intensity)

(7) Flow Control Valve: Electrically controlled, flow adjustable from 0-300kg/min. Composed of a servo motor, electric cylinder, and limit executor, it controls the valve opening to regulate flow. The PLC monitors current to ensure it matches the set value and automatically compensates. Current control accuracy is ±1%.

3.7 Dust Collection System (Dry Cartridge Dust Collector)

(1) The equipment uses a dry cartridge pulse-jet reverse blow dust collector, providing dust collection and airflow circulation within the shot blasting chamber. The dust collector's shell is made of ≥4mm thick steel plates with a support structure. The lower part is a sealed ash hopper and a wheeled ash car (using unorganized emission).

(2) With 12 filter cartridges, it can handle an air volume of up to 6000m³/h, with dust emission concentration below 10mg/m³. The dust collection fan is equipped with a silencer to reduce noise to ≤85dB(A) at 1m from the equipment. The dust collection system also features a calcium carbonate CaCO₃ automatic fire extinguishing device to reduce the risk of dust collector fires.

(3) The lower end of the dust collector is fitted with an ash bag and a wheeled ash car with good sealing. Operators only need to regularly clean the dust from the car.

(4) The equipment is equipped with explosion-proof devices, including dust relief valves, differential pressure gauges, fireproof butterfly valves, temperature sensors, and dust collection ports that cannot be ignited by open flames.

(5) The dust collector is equipped with a pulse-jet reverse blow device that sends compressed air into the center of the filter cartridges to clean dust from their outer walls. The PLC controls the frequency and duration of cartridge back-blowing.

(6) Noise reduction design: The fan outlet is equipped with a silencer, and the bottom is fitted with vibration dampers and a soundproof hood lined with sound-absorbing material to reduce operating noise.

(7) The dust collector is equipped with a pressure difference sensor that triggers an alarm when the pressure difference between the inside and outside of the filter cartridge reaches a warning level, reminding operators to replace the filter cartridge in time.

(8) The dust collection fan is equipped with a low-noise centrifugal fan, bearings, an overall support frame, and vibration pads. The dust collection ducts feature electrostatic discharge lines for anti-static functionality.

(9) The installation of the dust exhaust chimney pipeline, as well as the fabrication and installation of inspection ports and platforms, is the responsibility of the buyer.

3.8 Electrical Control System

The electrical control system consists of electrical hardware and software components, complying with the IEC standard.

3.8.1 Electrical Hardware Components

(1) The shot blasting chamber is equipped with an electrical control cabinet with an air conditioner. The cabinet color is RAL7035 (customizable upon buyer's request). The design is simple and elegant, with robust construction, neat wiring, clear labeling, and fine craftsmanship.

(2) The cabinet includes a computer tray and a steel file bag.

(3) The exterior of the cabinet is equipped with an industrial cabinet air conditioner for enhanced safety.

(4) Power requirements: Three-phase five-wire system, 380/220VAC±10%, 50Hz±1Hz. Power is approximately 62kw.

(5) Control voltage: DC220V±10％, 50Hz±2％.

(6) MIZHI intelligent controller and Schneider electrical components.

(7) The top of the electrical cabinet is equipped with a tri-color alarm light.

(8) The electrical cabinet door has manual/automatic buttons, automatic start button, automatic stop button, and fault reset button.

(9) The equipment is equipped with a 12-inch touch screen. A dual-hand control station is provided at the operator's position for convenience.

(10) An Ethernet interface is available for computer use, with the requirement to provide PLC and touch screen original programs.

(11) Power guarantee of approximately 70KW, with 50 square millimeter cables. Requires 1-inch water inlet pipe, 2.5-inch drain pipe, and 1-inch small air pipe.

3.8.2 Electrical Software Components

1.Electrical Operation Interface

The touch screen features interfaces such as "Main Unit Monitoring," "Parameter Setting," "Equipment Maintenance," "Cost Management," "Alarm Monitoring," and "Technical Support."

a) On the left side of the overall machine monitoring interface are the mechanisms that can be started and stopped manually. On the right side of the diagram, each motor and circuit are displayed in real time in different colors to show the operation status of the equipment.

b) Parameter setting: Through this screen, the operator can set the shot blasting parameters and view the feedback values of each parameter in the equipment.

c) Through this interface, staff can set the process parameters of this part and set the parameters according to the process requirements.

d) (White is the set value and green is the actual feedback value).

e) Maintenance screen, through which the operator can understand the mechanisms in the equipment that require frequent maintenance and the maintenance cycle of these mechanisms.

f) Understand the operating time of the equipment and the shot blasting operating time.

g) Cost management can prompt users to check and replace vulnerable parts in a timely manner, and the service life can be adjusted according to usage conditions.

h) Alarm screen. Through this screen, the operator can view the alarm records of the equipment.

i) Technical support: Customers can learn about our company's contact information through this screen.

j) Data storage is maintained for half a year, and more than 500 process programs can be stored.

3.9 Maintenance Platform

(1) The maintenance platform is divided into upper and lower layers to secure the separator and hopper, facilitating access to all components for maintenance or repair.

(2) The platform is constructed from thick square pipes and grating boards.

(3) The upper platform is equipped with safety railings painted in warning yellow. A kick plate is installed at the bottom of the railing.

(4) A vertical ladder is installed on the upper platform for easy access during maintenance.

3.10 Equipment Instruction Manual (Three Chinese Paper Copies and One Electronic Copy)

The instruction manual includes the following content:

l Safety Regulations

l Equipment Technical Specifications

l Equipment Operation Instructions

l Equipment Maintenance Instructions

l Electrical and Mechanical Drawings

l External Component Manuals

l Spare Parts List

l PLC Program

4.List of Major External Components Suppliers

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