Effective and maintained shot blasting machine: For safety of workers

July 9, 2019 3:05 pm

An analysis by industry experts on an effective use and maintenance of shot blasting machine and the safety of workers working on it.

Shot blasting machine is a kind of casting equipment which cleans or strengthens the surface of the work piece by the high-speed running shots. However, since the shots of shot blast machine runs in high speed, the maintenance of the equipment and operation is highly important. Much attention should be paid during maintenance of shot blasting machine.

Effective use and maintenance of shot blasting machine
Shot blasting machine is a self-destructive machine, as the name suggests it requires regular maintenance for its effective operation and performance. Every user should take utmost care of the machine, particularly the blast wheel. A majority of problem with the machine is directly influenced by the blast wheel. Problems such as high blast cycle time, excessive vibration and noise, cabin wear out, leakages, high media consumption, inadequate cleaning etc, are caused or heavily influenced by the blast wheel.

Ebin Abraham, Proprietor, Crystal Group states, “Effective use of the blast machine can be ensured with proper maintenance of the blast wheel. A properly maintained and set blast wheel will hit the target with minimum deviation and maximum velocity which mean the media propelled by a well maintained wheel will hit the component with minimum losses and minimum damage to the blast cabinet and machine thus reducing cycle time, cabin wear and media consumption.”

Nowadays, with the development of advance sensors and AI, OEMs are coming up with systems which will not only alert the user but also will take necessary steps to correct the situation. For example manufacturers are coming up with self adjusting control cage which automatically corrects the control cage setting compensating for its lip wear. Such systems will effectively reduce the downtime, premature wear of blast liners and will improve the performance of the machine.

According to Vipin Chawla, Proprietor, Vands Engineering Solutions, “Worn out impeller blade, turbine wheel and control cage are the items to be replaced frequently because this machine gets damaged by itself if the high manganese steel plate, rubber sheet and other protective devices in the shot blast cleaning chamber are worn so replace them immediately. Otherwise, the shots might hit through the wall of the chamber, fly out and hurt the personnel around.”

Blast cleaning can be an extremely effective way to prepare a part for coating. But if the machine isn’t set up, maintained, or monitored properly, the operation can go awry. Shot blasting means process where abrasive is bombarded at an object in order to get the desired finish.

Chwala adds, “Vands Engineering Solutions are specialised in reducing maintenance of machine by providing high quality spares. New inventions have been made in the material of spare we provide spares with new material like high abrasion resistant castings, tool steel, spares with tungsten carbide coating.”

Abraham says, “At Crystals, we are coming up with blast wheels which will reduce machine downtime, reduce maintenance analysis, easy to fit and advance alert system which will indicate the user where the problem is, what is to be replaced and when to replace. Alert systems like such will highly improve machine performance and can save on costly spares, skilled man force, unpredicted breakdowns and effective use of media.”

Maintaining safety of workers working on shot blasting machines
Shot blasting is a specialised process which is hazardous to health and safety of the workers and can also lead to accidents and respiratory problems. First and foremost, the workers should be trained in safe work practices on the blasting machine. The do and don’t should be clearly specified on the machine. As there can be dust, noise and flying media the workers should always wear safety glasses, air mask and ear plugs. Even the workers who work near the shot blasting machine are recommended to follow the same safety guidelines as that of shot blasting. Flying media and media on the shop floor attributes to accident such as damage to eyes and slipping on the floor.

Another major issue is that, pertaining to the safety of workers and the equipment is dust collector fire. There are many cases where dust collectors have caught fire and one of the main culprits is welding or any hot process carried out within or on the machine. Components with oil residues are also one of the cause for the same. If welding or cutting is required to be done for maintenance then it is recommended that all the blast gates on the ducting line to be closed, it would be safer if one piece of the ducting to be removed before carrying out these processes. For oily components it is recommended that the duct lines, dust collector and dust bags to be cleaned on regular intervals.

Abraham assures, “OEMs, nowadays, provide active and passive safety measures to avoid and counteract such scenario by introducing systems such as spark arresters, fire and smoke detectors, water sprinklers, explosion vents etc. automated blast gates are implemented on machines to shut off automatically when in maintenance mode.”The condition of the shot blasting machine is a major factor when it comes to the safety of workers and the equipment.

OEMs, nowadays, provide active and passive safety measures to avoid and counteract scenario by ensuring the use of safety equipment.
Ebin Abraham, Proprietor, Crystal Group

Blast cleaning can be an extremely effective way to prepare a part for coating. But if the machine isn’t set up, maintained, or monitored properly, the operation can go awry.
Vipin Chawla, Proprietor, Vands Engineering Solutions