我公司原用通过式悬挂抛丸机对客户的锻件进行表面抛丸处理，该设备因是传统的通过式，抛丸室进出口靠多层皮子挡钢丸，造成密封不严，设备漏砂严重，钢丸收回比例低，造成锻件抛丸后表面不光滑，发乌发暗，影响锻件表面质量。本文结合公司几十年锻件生产经验和技术积累，总结出提升锻件表面抛丸质量几点要素，设计、制造了步进式悬挂抛丸机，满足产品质量要求，提高了产品市场竞争力。新抛丸机采用自动化控制，喷丸效率提升，同时节约了人工成本。

　　Our company originally used a through type suspension shot blasting machine to perform surface shot blasting treatment on customers' forgings. Due to the traditional through type equipment, the entrance and exit of the shot blasting chamber rely on multiple layers of leather to block the steel shot, resulting in poor sealing, severe sand leakage, and low steel shot recovery ratio. This causes the surface of the forgings to be uneven, black and dark after shot blasting, affecting the surface quality of the forgings. This article combines the company's decades of experience and technological accumulation in forging production to summarize several elements for improving the surface shot blasting quality of forgings. A stepper suspension shot blasting machine has been designed and manufactured to meet product quality requirements and enhance product market competitiveness. The new shot blasting machine adopts automated control, which improves shot blasting efficiency and saves labor costs.

　　新抛丸机简介

　　Introduction to the new shot blasting machine

　　抛丸机工作流程

　　Shot blasting machine workflow

　　抛丸工作流程见图1。抛丸机由PLC 控制，除尘器、弹丸循环系统启动运行，等待生产。上料区操作工通过悬臂吊装料后，通过悬链输送系统将待处理锻件送至抛丸室内待喷区域后停止，抛丸室门关闭，自转系统开启，在自转机构的驱动下，吊钩总成带着零件以链轮传动的方式旋转，此时抛丸器与弹丸闸门打开，抛丸清理旋转的锻件。自转机构加装变频器，通过调节变频器来控制自转速度大小来保证锻件抛丸无盲区。

　　The shot blasting workflow is shown in Figure 1. The shot blasting machine is controlled by PLC, and the dust collector and shot circulation system start running, waiting for production. After the loading area operator uses a cantilever crane to load materials, the forging to be processed is transported to the spraying area in the shot blasting room through a chain conveyor system and then stopped. The shot blasting room door is closed, and the self rotation system is opened. Under the drive of the self rotation mechanism, the hook assembly rotates with the parts in a chain wheel drive manner. At this time, the shot blasting machine and shot blasting gate open, and the rotating forging is shot blasted and cleaned. Install a frequency converter on the rotation mechanism, and control the rotation speed by adjusting the frequency converter to ensure that the forging shot blasting has no blind spots.

　　清理完毕，弹丸闸门和抛丸器关闭，抛丸室大门打开，自转装置停止，悬链输送系统将清理区域内的锻件传送出抛丸室，同时等待区上的锻件快速进入抛丸室，关闭抛丸室，开启自转装置带动锻件旋转，开启抛丸器下料闸门，开始下一次清理工作。操作工在上/卸料区同时进行装卸作业。

　　After cleaning, the shot blasting gate and shot blasting device are closed, the shot blasting chamber door is opened, the rotation device stops, and the suspension chain conveying system transports the forgings in the cleaning area out of the shot blasting chamber. At the same time, the forgings in the waiting area quickly enter the shot blasting chamber. Close the shot blasting chamber, open the rotation device to drive the forgings to rotate, open the shot blasting device discharge gate, and start the next cleaning work. Operators carry out loading and unloading operations simultaneously in the loading/unloading area.

　　悬挂抛丸机主要结构及特点

　　Main structure and characteristics of suspended shot blasting machine

　　抛丸机容量按调质炉锻件日产量设计为双工位悬链步进式抛丸清理机，主要由锻件悬链系统、抛丸室、弹丸循环系统、挂具自转系统、电气控制系统、除尘系统等组成。

　　The capacity of the shot blasting machine is designed as a dual station catenary walking shot blasting cleaning machine based on the daily production of quenched and tempered furnace forgings. It mainly consists of a forging catenary system, shot blasting chamber, shot circulation system, hanging tool rotation system, electrical control system, dust removal system, etc.

　　⑴锻件悬链系统。抛丸机悬链系统选用2 寸模锻链条，每个吊钩由两组负载滑架承载。被清理锻件通过挂具吊挂在吊钩上，悬链系统由驱动链轮带动，使锻件沿轨道步进式地行进。悬链走轮在工字钢下翼上运行，导轮用来防止吊钩进入抛丸器工作区时产生摆动。吊钩总成根据生产需要及场地限制设计10 个，每2 个一组，后期可根据需要增加数量。吊钩上侧加装一层下凹式的锰钢板，与一层轧制Mn13 高耐磨护板、多层耐磨胶板及清理室顶部挂钩行走槽处的尼龙毛刷共同组成迷宫式密封带，在有效防止弹丸反弹到室外的同时，防止钢砂对链条及走轮的损伤。

　　⑴ Forging suspension chain system. The suspension chain system of the shot blasting machine uses 2-inch forged chains, and each hook is supported by two sets of load slides. The cleaned forging is hung on a hook by a hanging device, and the suspension chain system is driven by a sprocket to move the forging step by step along the track. The hanging chain running wheel runs on the lower wing of the I-beam, and the guide wheel is used to prevent the hook from swinging when entering the working area of the shot blasting machine. 10 hook assemblies are designed according to production needs and site limitations, with each set consisting of 2 hooks. The quantity can be increased as needed in the later stage. A layer of concave manganese steel plate is installed on the upper side of the hook, which, together with a layer of rolled Mn13 high wear-resistant protective plate, multiple layers of wear-resistant rubber plates, and a nylon brush at the top of the cleaning room hook walking groove, forms a labyrinth sealing belt. It effectively prevents bullets from bouncing outside and prevents steel sand from damaging the chain and wheels.

　　⑵抛丸清理室。抛丸室体由型钢制成骨架，外侧用普通钢板条焊接而成，内侧用轧制锰钢焊接。抛丸室的钢结构件均要求设备厂家喷丸清理后喷防锈底漆，同时还具有强化时效功能，保证有足够的刚度和强度。室体内衬抛射热区为18mm 厚轧制Mn13 耐磨护板，非热区为14mm 厚轧制Mn13 耐磨护板，采用大块焊接方式固定，方便后期维护。抛丸室体顶部挂钩走槽采用成熟的迷宫式密封方法，结构精细，可最大限度地防止抛射的钢丸飞出抛丸室。清理室内设有地坪格栅，便于维修人员行走，并在格栅上铺设铸铬耐磨冲孔护板，防止较大块状物、飞边、毛刺进入漏斗、螺旋输送器和提升机，确保弹丸的正常循环，保证设备运转正常。抛丸室两侧进出口设有气动对开门，采用带缓冲装置的气缸驱动，大门开、闭平稳，无冲击，同时气缸上设有光电接收器，起联锁保护作用。抛丸室门采用10mm 厚轧制Mn13 护板保护，并在门框一圈设置环形橡胶防护，防止钢丸飞溅。抛丸室大门底部设有弹丸回收槽，方便开门时夹杂在门缝中的残留钢丸回收到室体内，防止弹丸四处散落，并达到弹丸回收利用的作用。

　　⑵ Shot blasting cleaning room. The shot blasting chamber body is made of profile steel skeleton, the outer side is welded with ordinary steel plates, and the inner side is welded with rolled manganese steel. The steel structural components of the shot blasting room require the equipment manufacturer to spray anti rust primer after shot blasting cleaning, and also have enhanced aging function to ensure sufficient rigidity and strength. The interior lining of the room is equipped with 18mm thick rolled Mn13 wear-resistant protective plate in the hot zone, and 14mm thick rolled Mn13 wear-resistant protective plate in the non hot zone. It is fixed by large welding to facilitate later maintenance. The hanging groove on the top of the shot blasting chamber adopts a mature labyrinth sealing method, with a fine structure that can prevent the ejected steel shot from flying out of the shot blasting chamber to the maximum extent. Clean the indoor floor grid for maintenance personnel to walk, and lay chrome wear-resistant punched protective plates on the grid to prevent large objects, flying edges, and burrs from entering the funnel, screw conveyor, and elevator, ensuring the normal circulation of pellets and the normal operation of equipment. Pneumatic double doors are installed at the entrances and exits on both sides of the shot blasting room, driven by cylinders with buffering devices. The doors open and close smoothly without impact. At the same time, photoelectric receivers are installed on the cylinders to provide interlocking protection. The shot blasting room door is protected by a 10mm thick rolled Mn13 guard plate, and a circular rubber protection is installed around the door frame to prevent steel shot splashing. The bottom of the shot blasting room door is equipped with a shot recovery groove, which facilitates the recovery of residual steel shot mixed in the door gap when opening the door, preventing the shot from scattering around and achieving the purpose of shot recovery and utilization.

　　⑶抛丸器总成。抛丸器布置方式经过设计团队多次研讨，在并列3 组6 台方式和并列2 组6 台方式之间进行取舍，由于现场空间受限及锻件长度决定，最终确认抛丸室侧壁上设计成并列2 组6 台抛丸器总成的布局(如零件长超过1300mm，建议采用2 组6 台方式；如果是正常6 缸曲轴类零件，建议使用3 组6 台方式)，将抛丸盲区降到最低。抛丸器电机采用西门子品牌，性能稳定可靠，根据老式抛丸机使用反馈经验，并结合制造厂商测算，抛丸量定在360kg/min，电机功率为22kW。新抛丸器舍弃主流的直连方式，而是采用皮带传动结构。根据十几年抛丸器使用经验证明，直连式抛丸机虽效率高，但是维护不方便，电机易损坏，采用皮带传动抛丸器，方便日常维护维修，同时降低抛丸器采购成本，抛丸效率可通过传动速比进行补偿。抛丸器外壳采用锰钢制成，侧面外壳钢板厚12mm，轴承端面和对面外壳钢板厚14mm，端盖钢板厚度可采用10mm。抛丸器内部零部件护板、定向套、分丸轮、叶片、叶轮等均采用现今流行的模具钢CNC 精密加工，加工精度达到±0.01mm。要求机加工后采用低压真空热处理方式，硬度为58 ～62HRC，硬度偏上，达到60 ～62HRC 为最佳，增加零部件耐磨度，若超过62HRC 零部件发脆，易断。经现场使用验证，使用丸料为φ1.5mm 以下铸钢丸(钢丸过大易损叶片，特别是钢丝切丸)，以上易损件使用寿命是铸造产品三倍以上。

　　⑶ Shot blasting machine assembly. After multiple discussions by the design team, the layout of the shot blasting equipment was chosen between the parallel 3 sets of 6 units and the parallel 2 sets of 6 units. Due to limited space on site and the length of the forgings, it was finally confirmed that the side walls of the shot blasting room should be designed with a layout of 2 sets of 6 shot blasting equipment assemblies in parallel (if the length of the parts exceeds 1300mm, it is recommended to use 2 sets of 6 units); If it is a normal 6-cylinder crankshaft component, it is recommended to use 3 sets of 6 units to minimize the shot blasting blind spot. The shot blasting machine motor adopts Siemens brand, with stable and reliable performance. Based on feedback from the use of old shot blasting machines and combined with manufacturer calculations, the shot blasting volume is set at 360kg/min, and the motor power is 22kW. The new shot blasting machine abandons the mainstream direct connection method and adopts a belt transmission structure. Based on more than a decade of experience using shot blasting machines, it has been proven that although direct connected shot blasting machines have high efficiency, they are not easy to maintain and the motor is prone to damage. Therefore, belt driven shot blasting machines are used to facilitate daily maintenance and repair, while reducing the cost of shot blasting equipment procurement. Shot blasting efficiency can be compensated by the transmission speed ratio. The shell of the shot blasting machine is made of manganese steel, with a thickness of 12mm for the side shell steel plate, 14mm for the bearing end face and the opposite shell steel plate, and 10mm for the end cover steel plate. The internal components of the shot blasting machine, such as the protective plate, directional sleeve, dividing wheel, blade, impeller, etc., are all CNC precision machined with popular mold steel, with a machining accuracy of ± 0.01mm. It is required to use low-pressure vacuum heat treatment after machining, with a hardness of 58-62HRC, and the best hardness is 60-62HRC, which increases the wear resistance of the components. If the hardness exceeds 62HRC, the components will become brittle and easy to break. After on-site verification, it has been found that the use of steel shot with a diameter of less than 1.5mm (especially steel wire cutting shot, which can easily damage blades due to excessive steel shot) has a service life of more than three times that of cast products for the above vulnerable parts.

　　⑷弹丸循环系统。弹丸循环系统由螺旋输送器、斗式提升机、丸砂分离器、气动供丸闸阀、溜丸管等组成。见图2。图2 弹丸循环系统抛丸室底部的螺旋输送器采用纵向和横向两种方式，负责将室体底部溜丸斗所收集的弹丸经溜丸槽输送至斗式提升机，螺旋输送器的一端轴头按行业标准配制脉冲轮，可检测跟踪螺旋输送器的工作状态，一旦出现卡阻等故障，可及时将信号反馈至PLC 进行处理，保证设备的安全运转。斗式提升机由驱动电机，减速器，主、被动轮，输送带，挖砂斗和张紧装置等组成。提升机的下端进料口接螺旋输送器，上端出料口接分离器。分离器采用现常用的满幕帘风选式丸渣分离器。分离效率不低于99%。供丸系统采用SC 型气缸控制的供丸闸门。吊钩自转机构由减速机、主动链轮、链条、减速机机座等组成，使定位吊钩上的链轮与自转链条相啮合，保持抛丸过程中工件始终处于旋转状态，适当调整减速机机座便可保持自转链条的松紧度。

　　⑷ Bullet circulation system. The pellet circulation system consists of a screw conveyor, bucket elevator, pellet sand separator, pneumatic pellet gate valve, and pellet chute. See Figure 2. The spiral conveyor at the bottom of the shot blasting chamber in Figure 2 adopts two methods: longitudinal and transverse. It is responsible for conveying the pellets collected by the bottom of the chamber through the chute to the bucket elevator. One end of the spiral conveyor shaft is equipped with a pulse wheel according to industry standards, which can detect and track the working status of the spiral conveyor. Once there is a jamming or other fault, the signal can be promptly fed back to the PLC for processing to ensure the safe operation of the equipment. The bucket elevator consists of a drive motor, a reducer, active and passive wheels, a conveyor belt, a sand digging bucket, and a tensioning device. The lower inlet of the elevator is connected to a screw conveyor, and the upper outlet is connected to a separator. The separator adopts the commonly used full curtain air selective pellet separator. The separation efficiency is not less than 99%. The pill supply system adopts SC type cylinder controlled pill supply gate. The hook rotation mechanism consists of a reducer, an active sprocket, a chain, a reducer base, etc., which enables the sprocket on the positioning hook to mesh with the rotation chain, keeping the workpiece in a rotating state during the shot blasting process. Adjusting the reducer base appropriately can maintain the tightness of the rotation chain.

　　⑸除尘系统(脉冲离线清灰)。抛丸器除尘系统采用三级除尘，含尘气流经除尘管道、惯性沉降室、旋风除尘器、脉冲除尘器、排风机和排风管道排入大气。惯性除尘器将空气中的粉尘分离出来，使颗粒较大的粉尘下沉。再经过旋风除尘器，过滤掉大部分的灰尘，这样就减少了精密除尘器入口处的灰尘浓度，从而达到更好的除尘效果。最后经脉冲滤筒除尘器进行精过滤，达到排放标准(河南省标准是10mg/m3，高于国家标准20mg/m3)，最后通过风机、烟囱排入大气。

　　⑸ Dust removal system (pulse offline dust cleaning). The shot blasting dust removal system adopts three-level dust removal, and the dust containing gas flows through the dust removal pipeline, inertia settling chamber, cyclone dust collector, pulse dust collector, exhaust fan and exhaust pipeline and is discharged into the atmosphere. Inertial dust collectors separate dust from the air, causing larger particles of dust to sink. After passing through the cyclone dust collector, most of the dust is filtered out, which reduces the dust concentration at the entrance of the precision dust collector and achieves better dust removal effect. Finally, the fine filtration is carried out through a pulse filter cartridge dust collector to meet the emission standards (the standard in Henan Province is 10mg/m3, which is higher than the national standard of 20mg/m3), and finally discharged into the atmosphere through fans and chimneys.

　　⑹电气控制系统。抛丸设备采用西门子(S7-200SMART)PLC 集中控制控制系统运行，安全可靠，操作灵活，维修方便。系统具有故障实时报警显示装置，设备有过载保护装置，短路保护装置，整套系统采用了多种控制方法，使调试、维修人员能够更轻松地对设备进行调整。这时，操作工可按顺序依次启动各功能部件，也可以为了测试各相关部件的性能、运行状况等而不按顺序点动操作单个功能部件(如提升机、抛丸器)。为了保证正常安全运行，设备配有报警装置，若在生产过程中发现某一运动部位出现故障，就会立即报警，停止全线运行。这套系统主回路主要完成电能的分配和控制，以控制每台单机电动机为主要目的。主回路各支路由小型高分辨断路器实现短路保护，由热继电器实现过载及缺相保护。控制回路以可编程控制器(PLC)为核心，配以主令开关元件、检测元件、指示元件及报警单元等，采集和传输PLC 所需的各种输入信号和输出信号。该装置具有弹丸循环系统失效报警功能，系统内任意部位失效，为防止弹丸卡壳烧毁电动机，使供丸闸门自动关闭，停止运转。抛丸器的电流(反映供丸闸的流量)以电流表显示，同时将此电流值转换为标准的4 ～20mA 电流信号，传送给整合在PLC 上的模拟量输入模组，让PLC可以实时得知抛丸机若因马达热保护、空气开关未关闭、电气元件失效或弹丸流量不足而造成流速过小的情形。报警发出，抛丸清运工作禁止进行。

　　Electrical control system. The shot blasting equipment adopts Siemens (S7-200SMART) PLC centralized control system for operation, which is safe, reliable, flexible in operation, and easy to maintain. The system has a real-time fault alarm display device, and the equipment has overload protection device and short circuit protection device. The entire system adopts multiple control methods, making it easier for debugging and maintenance personnel to adjust the equipment. At this point, the operator can start each functional component in sequence, or they can operate individual functional components (such as elevators, shot blasting machines) in a non sequential manner to test the performance, operating conditions, and other related components. In order to ensure normal and safe operation, the equipment is equipped with an alarm device. If a malfunction is found in a moving part during the production process, an alarm will be immediately triggered and the entire line will be stopped. The main circuit of this system mainly completes the distribution and control of electrical energy, with the main purpose of controlling each individual motor. Each branch of the main circuit is equipped with small high-resolution circuit breakers for short-circuit protection, and thermal relays for overload and phase loss protection. The control circuit is centered around a programmable logic controller (PLC), equipped with master switch components, detection components, indicator components, and alarm units, etc., to collect and transmit various input and output signals required by the PLC. The device has a failure alarm function for the projectile circulation system. If any part of the system fails, in order to prevent the projectile from jamming and burning the motor, the supply gate will automatically close and stop running. The current of the shot blasting machine (reflecting the flow rate of the shot blasting gate) is displayed on an ammeter, and this current value is converted into a standard 4-20mA current signal, which is transmitted to the analog input module integrated on the PLC. This allows the PLC to know in real time if the shot blasting machine has a low flow rate due to motor thermal protection, air switch not turned off, electrical component failure, or insufficient shot flow. Alarm issued, shot blasting and cleaning work is prohibited.

　　锻件抛丸质量提升要素经过常年抛丸设备使用经验的积累总结出抛丸机主要依靠以下几个要素提升锻件表面质量：⑴抛丸室密闭设计杜绝跑钢丸；⑵根据一次抛丸锻件总重和数量确定抛丸器选取的数量和位置分布；⑶钢丸的选取决定锻件抛丸后表面粗糙度和亮度，推荐使用φ1.2mm 铸钢丸效果最佳，如想降低生产成本可使用φ1.5mm 以下钢丝切丸；⑷除尘设备风量的设计选用应大于理论值15%，保证零件表面无粉尘残留，保证下道除锈工序效果更佳。

　　After years of experience in using shot blasting equipment, it has been summarized that shot blasting machines mainly rely on the following elements to improve the surface quality of forgings: (1) The closed design of the shot blasting chamber prevents steel shot from escaping; ⑵ Determine the quantity and location distribution of shot blasting equipment based on the total weight and quantity of each shot blasting forging; The selection of steel shot determines the surface roughness and brightness of forged parts after shot blasting. It is recommended to use steel shot with a diameter of 1.2mm for the best effect. If you want to reduce production costs, steel wire cut shot with a diameter of less than 1.5mm can be used; The design and selection of air volume for dust removal equipment should be greater than the theoretical value by 15% to ensure that there is no dust residue on the surface of the parts and that the next rust removal process is more effective.

　　结束语

　　Conclusion

　　本文结合总结数据设计步进式悬挂抛丸机，对被清理锻件进行表面清理和去氧化皮(铸态铸件及正回火后铸件)，能有效提升热处理后锻件表面抛丸质量，提高产品市场竞争力的同时，通过自动化控制降低操作工劳动强度，提升操作人员现场工作安全环境。

　　This article combines summary data to design a step-by-step suspension shot blasting machine, which can effectively improve the surface shot blasting quality of the cleaned forgings (as cast castings and castings after normal tempering), enhance product market competitiveness, and reduce the labor intensity of operators through automatic control, thereby improving the safety environment for on-site work of operators.

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　　This article is a friendly contribution from an automatic shot blasting machine For more related knowledge, please click http://www.sdcjtz.com/ Sincere attitude To provide you with comprehensive services We will gradually contribute more relevant knowledge to everyone Coming soon.

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