True to our “finding a better way…” motto, Rosler partnered with thyssenkrupp AG to create a continuous flow shot blasting operation for the fastest crankshaft forge shop in the world.
World renowned for its drive trains, chassis, and automobile manufacturing equipment, the automotive division of thyssenkrupp AG significantly contributes to the technical progress and efficiency of motor vehicles. The thyssenkrupp Gerlach GmbH plant in Homburg, Germany, is a leading partner for the development of automobile engine components, offering a full-service package ranging from component design, prototype fabrication, and full-scale production.
Developing a Solution
To improve cost efficiency at its Homburg plant and to meet all customer requirements, thyssenkrupp AG installed its high-tech “production line 19” for forged crankshafts for engines with one to four cylinders in 2016. For this line, Rosler developed an innovative shot blast equipment concept known as the Rosler RKWS crankshaft shot blasting system.
The Long-life Rutten has the longest ultimate life expectancy of any, lasting upto 20 times longer than a standard blast wheel or turbine.
This is a highly-engineered blast wheel with exceptionally tight tolerances and built-in specialist superior steel alloys. Due to the higher value materials and the high specification machining costs of these materials, the initial investment and cost of component wear parts are more highly valued.
However, if maintenance and/or production problems are presently a big issue, the economics of this blast wheel can be demonstrated in ultimately high production speeds and demanding applications.
Least Maintenance And Highest Specifications
Less costs for maintenance up to 16 times higher wear resistance and service life of up to 40,000 operating hours (over 18 years on a single shift).
The proven Rutten Long-Life turbines, equipped with components made from carbide steel are characterised by their extremely long service life of up to 40,000 operating hours resulting in significantly higher equipment uptimes and drastically reduced time requirements for maintenance.
They offer substantial savings in energy consumption and spare part costs/hour. The blades have a precise design with a high recognition value and in addition allows the “Y” blade to be turned and used twice. Long-Life turbines are installed in a wide range of new shot blast equipment and can be easily retrofitted into existing shot blast machines.
Wear parts in your shot blast machine are the: blades/vanes, control cage, impellor and side / top wear plates in the blast wheel(s) themselves and the wear protection plates in the blast zone (in the area calculated to have the most impact from the abrasive when it is thrown from the wheel).