Tag Archives: Tips

Mass Finishing Machine Settings Series, Part 2 – Determine Imbalance Weight Settings for Consistent Results

Specific mass finishing applications are developed through processing trials. Once defined, users should not deviate from the determined machine settings unless necessitated by work piece or process changes.

Rosler partners with clients to provide testing in our global Customer Experience Centers to demonstrate our capabilities on a specific work piece and to calibrate machine settings. Determining the exact machine settings requires considering and testing multiple factors.

Vibratory Systems

The most common drive systems in mass finishing are vibratory. This refers to actual finishing machines such as rotary, tub, and linear continuous flow vibrators as well as auxiliary equipment like screening systems, vibratory conveyors, buffers, etc.

In all of these cases, the speed of the vibratory motor or the electric motor driving the imbalance unit(s) may have to be adjusted as well as the setting of the imbalance weights.

Vibratory weight plates

The angle between the upper and lower imbalance weights determines the movement of the media and work piece mix within the machine.

The number (mass) of imbalance weights determines the processing intensity (amplitude). More weights produce higher intensity while fewer weights deliver lower intensity.

Cutaway diagram detailing vibratory motor parts including upper and lower imbalance weights and the electric motor
Vibratory motor diagram

Setting Imbalance Weights

The movement of the media/work piece mix is always opposite to the motor direction. Typically, the motor runs clockwise and the media/work piece mix runs counter clockwise.

In some instances, the motor can run clockwise and counterclockwise including the Rosler “R” machines and gate clearing in Rosler “Euro” machines.

Half-circle metal plate weights on the top and bottom of the motor must be positioned with respect to each other. For a basic setting, the bottom weight plate must be turned 90 degrees forward of the top weight plate, in a basic setting.

Imbalance weights locations and settings within a vibratory motor
Imbalance weights locations and settings within a vibratory motor

When setting imbalance weights, it is important to understand the impact of changes. For example, increasing the lead angle will make the media/work piece mix travel around the work bowl faster. Decreasing the lead angle will have the opposite effect, slowing movement.

Typical lead angles range from 70 to 120° and can be observed by checking the gauge on the top of the motor shaft.

image showing vibratory motor lead angle gauge
Vibratory motor lead angle gauge

Within the imbalance weights, the top weight controls the travel speed of the media/work piece mix around the work bowl. Adding additional weights to the top will increase the travel speed while decreasing the spiral speed in the work bowl.

The top imbalance weight controls media and workpiece speed around the work bowl as represented by the red arrow while the bottom imbalance weight controls the spiraling speed of the work bowl contents.
The top imbalance weight controls media and workpiece speed around the work bowl as represented by the red arrow while the bottom imbalance weight controls the spiraling speed of the work bowl contents.

The bottom weight controls the spiral speed of the media/work piece mix in the work bowl. Conversely to the top weight, adding additional weights to the bottom will increase the spiral speed but also decrease the travel speed around the work bowl.

Action Points

Regularly checking a mass finishing machine’s settings including motor speed(s), setting of imbalance weights, work station angles, etc. to ensure they are as initially established will produce better results and protect the systems ROI.

A vibrocope sticker on the work bowl allows for a quick check of the processing intensity. Additional information can be found in our Using Vibrascope to Measure Amplitude v. Frequency in Vibratory Bowls blog post.

photo of a vibroscope sticker
Virboscope sticker

Additionally, if repairs require drive motors to be disconnected, make sure that they are rewired correctly and are not running in the wrong direction.

If the machine settings must be changed, carefully follow the instructions in your operator’s manual or consult the manufacturer for assistance.

If not already integrated, installation of a frequency inverter for precise setting of the drive speed of your machine may be available as an upgrade, providing additional control and oversight.

The Rosler Way

Rosler goes beyond developing mass finishing machines to provide operational insight and guidance for the lifetime of our machines as well as consumables and service. Contact us to discuss your needs and our capabilities.

The Mass Finishing Machine Settings Series also includes Part 1 – Improve Machine Function with Proactive and Responsive Observation, Calibration.

Preventative Maintenance Enables Mass Finishing Equipment to Go the Extra Mile

Mass finishing machines are workhorses of industrial finishing operations, combining engineering expertise and often a hefty price tag. When preformed according to manufacturer recommendations, preventative maintenance can make a big difference in the length of time between design and decommissioning.

Not convinced? Think of your mass finishing equipment like a vehicle. What would happen if you never checked the air pressure in your tires, changed the oil, or replaced the brake pads? Eventually your vehicle would leave you stranded on the side of the road through no fault of its own.

Mass finishing equipment manufactured by a proven expert such as Rosler is just the same as a vehicle that didn’t get the care it deserved. Without preventative maintenance, your high-dollar investment will break down. However, by performing preventative maintenance according to the manufacturer’s recommendations, your equipment will operate like a well-cared for vehicle, extending the life and return on your initial investment.

Diesel or unleaded fuel, anti-lock or drum brakes, manual transmission or automatic, preventative maintenance varies by vehicle type. Here are considerations for preventative maintenance based on your specific mass finishing equipment type.

Read more about preventative maintenance

Optimized Finishing Processes Can Reduce Operational Costs

You don’t throw your media out with the waste water, so why would you purchase new mass finishing equipment or muddle through with an inefficient process when optimization can extend the life and enhance the effectiveness of your processing equipment?

Whether a result of increased production needs or in response to poor performance, optimizing your mass finishing process is a great way to reduce operational costs and lower your equipment’s total cost of ownership.

A Proactive Approach

Revising a process to meet increased production demand is a cost-effective way to not only improve your processing times and results, but also increase and prolong your equipment’s usefulness.

Let’s say production has been steadily building over time. How do you know if it’s time to evaluate the process?

Continue reading Optimized Finishing Processes Can Reduce Operational Costs

8 Considerations When Purchasing a Rotary Vibratory Machine

Buying Mass Finishing equipment, as with all investments, can be a bit overwhelming at first.   There will surely be a number of suppliers and machine types available to you.  In order to ensure you get the best value for your money we recommend you consider the following when purchasing a rotary vibratory machine:

Movement– Appearances can be deceiving, don’t be fooled into thinking all machines are the same just because the look similar.  Always test the machine and its processing ability before you buy!  Test its amplitude, see how regular the movement is, is it consistently driving the same way?

Strength and durability – Check how heavy the machine is, usually you’ll find something costs less because it is made of cheaper and lighter materials.

Continue reading 8 Considerations When Purchasing a Rotary Vibratory Machine

THE 9 MOST COMMON MISTAKES YOU NEED TO AVOID TO GET THE MOST OUT OF YOUR MASS FINISHING MACHINE

When maintained properly, mass finishing equipment can be very user friendly.

As a result sometimes operators can get into the habit of just turning them on each day and ignoring simple operating and maintenance rules.  Avoiding the following 9 mistakes that operators commonly make will help you get the most from your equipment:

  • They let the media level drop, often with the aim of saving money or so they can get more work pieces in. This changes the ratio of work pieces per media though and can affect process times, unloading ability, can cause components to damage each other, and can result in the required finish not being achievable.

Continue reading THE 9 MOST COMMON MISTAKES YOU NEED TO AVOID TO GET THE MOST OUT OF YOUR MASS FINISHING MACHINE

Tips to optimize your surface finishing process – Tip #3

 

Tip #3 – Optimum operating conditions

Once a mass finishing process has been established by the selection of machine, media and compound, the system must be constantly monitored and, of course, properly maintained. The good news is, this is quite easy! By following a few simple quality control rules, the process will remain absolutely stable, producing the desired finishing results for many years:

Read more about optimum operating conditions

Tips to optimize your surface finishing process – Tip #2

Tip #2 – The need for processing trials

Of course, the selection of the right machine, media and compound can sometimes be a bit intimidating. Not only does a mass finishing user have to choose among a wide variety of machine types and sizes, they must also pick the right media from hundreds of media types, shapes and sizes. And on top of all this Read more about processing trials

Tips to optimize your surface finishing process- Tip #1

Tip #1 – The work pieces are always at the center

The development of any surface finishing solution always revolves around the work pieces. Their material, size, shape and above all, the finishing objectives, determine what type of finishing process must be selected.

The work piece size is especially important. For example, the deburring and edge

Read more about work pieces

The 9 critical points to check you get the most out of your mass finishing machine and process

Here are 9 critical points to help you get the most out of vibratory finishing:

1. Regularly Check That You Have Enough Media In Your Machine.

2. Check That The Media Condition Is Good.

3. Check You Have The Right Amount Of Water And Compound In The Machine.

4. Regularly Check Your Drains.

5. Too Many Parts In The Machine.Mass Finishing Machine Tips Booklet_Page_2_Image_0001

6. Check The Machine Is Running The Correct Way.

7. Check The Machine Lining Is In Good Condition.

8. Check You Are Following The Process Parameters.

9. Check Your Starting Condition Is The Same.

Shot Blast Tips

Here are 9 critical points to help you get the most out of shot blasting:

1. Regularly Check That You Have Enough Abrasive In Your Machine.

2. Regularly Check That Your Abrasive Working Mix Is Correct.

3. Check That The Abrasive Condition Is Good.

4. Ensure Contaminants Are Removed.

5. Monitor Your Abrasive Removal Size.Wear Parts

6. Regularly Check Your Wear Parts.

7. Check Your Blast Pattern.

8. Check Your Blast Wheel Amp Efficiency.

9. Check Your Starting Condition Is The Same.