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ROBOTIC SHOT PEENING SYSTEM

Published by Guyson on July 30, 2010

Guyson Corporation has introduced a 7-axis robotic pressure-blast shot peening system that is designed to support compliance with the most demanding process specifications and to enable automated peening of a wide variety of
dissimilar components. The Model RB-10 was developed for technical surface treatment of gears and aerospace components.

7-axis robotic shot peening system for gears and aerospace components

The Guyson RB-10 Shot Peening System introduces a new dimension of flexibility in precision surface treatment to NADCAP quality standards.

The 60 x 60 x 60-inch blast cabinet is mated with a 6-axis robot, such as the Fanuc M10iA,
as a blast nozzle manipulator. The shot peening machine’s rotary table has a diameter of up
to 52 inches and is servomotor driven to be controlled as a seventh axis of robotic motion.
Locating hardware is provided to allow interchangeable component-holding fixtures to be
positively and repeatably positioned on the turntable.

During the shot peening cycle, the orientation of the component and the motion of the robotic
nozzle manipulator are synchronized to precisely replicate the programmed tool path,
following the contours of complex-shaped parts, yet constantly and accurately maintaining
the required angle of shot impingement, the correct offset of the peening nozzle from the
target surface and the right dwell or surface speed to control the cold working process.

The peening media delivery system includes an A.S.M.E.-certified pressure vessel of 3.5
cubic foot capacity fitted with high and low shot level sensors, a 3 cubic foot media storage
hopper that automatically adds shot when a low level is detected and, if required, an
electronic shot flow controller to continuously maintain the correct blast pressure and shot
flow rate specified for the shot peening process.

In addition to a cyclone separator for dust extraction, the shot reclamation system includes a
vibratory screen classifier to deliver only shot of the specified size, as well as a spiral
separator to remove any peening shot that is not perfectly spherical.

For metallurgical shot peening applications in accordance with S.A.E. aerospace peening
specification AMS 2432, Guyson offers a SCADA controls package combined with a custom-
designed touch screen human-machine interface (HMI) to enable data verifying all critical
process parameters throughout the shot peening procedure to be captured and logged for
documentation purposes.

Prospective users of robotic shot peening equipment are encouraged to submit sample components for
evaluation in the application engineering laboratory at Guyson’s design and manufacturing center in
northeastern New York State.

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ROBOTIC BLAST MACHINE HAS TRANSFER CART

Published by Guyson on May 10, 2010

Guyson Corporation has introduced a robotic blasting system that incorporates a component-manipulating 6-axis robot and a shuttle transfer cart to fully automate processing of tray-loads of components. The new Model RB-TRR-900 is designed for precise surface preparation, shot peening and cosmetic finishing operations.

RB-TRR-900 blast machine processes a tray-load of components automatically

Guyson RB-TRR-900 has a shuttle cart to transfer a tray of components in and out of the blast chamber, combining the precision and repeatability of robotic blasting with the efficiency of batch treatment.

The robotic blast machine is provided with a single suction-blast gun or pressure-blast nozzle that is rigidly bracketed in a fixed position inside the 42 x 42 x 42-inch blast chamber. Guide rails form a track extension into an antechamber on one side of the blast cabinet. Rolling on the track, the transfer cart bearing a tray full of components is moved in and out of the blast enclosure by a precision linear actuator, and a pneumatically actuated vertical sliding door closes to isolate the load/unload station from the blasting zone.

A Fanuc M-10iA robot with a custom-engineered pneumatic gripper serves as a component handler in the automated blasting system, grasping and removing a part from the tray, presenting the component to the blast, then replacing the finished work piece. A tailored skirt seals the cabinet wall and protects the robot from the potentially abrasive environment of the blast chamber. Fanuc Robotics offers larger and smaller 6-axis robots that can be integrated in the RB-TRR-900, should a different payload or reach be required.

To blast a production lot of parts, a tray of oriented components, typically 6 to 24 in number, is placed on the transfer cart, the sliding load door is closed and a part identification number is entered or selected at the touch-screen control panel. Alternatively, component recognition features are available, including a bar code reader, to positively identify the work and prompt the recall of the correct motion program and blasting process recipe, with automatically controlled parameters such as blast pressure, media flow rate and the duration of the blast and blow-off cycles. While the robotic blast system methodically and identically repeats the surface treatment on each of the components in the batch, the human operator is freed for an extended period to perform other work.

The robotic component manipulator constantly and accurately maintains the specified blast angle, nozzle offset and surface speed, even when following the contours of complex-shaped aerospace or medical parts, which makes it possible to produce extremely consistent surface conditions and eliminate non-conformities in finish quality.

Prospective users of automated and robotic blasting systems are invited to submit sample components for free laboratory testing and application engineering evaluation at Guyson’s factory in northeastern New York State.

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WORK CELL ROBOTIC BLAST MACHINE

Published by Guyson on March 12, 2010

Guyson Corporation has introduced a robotic blasting system based on one of its compact rotary suction-blast cabinets. The Model RB-RSSA-6 incorporates a Fanuc LR Mate 200iC robot and is designed for work cell blasting operations, such as blast cleaning, cosmetic finishing, coating removal and technical surface preparation.

Guyson work cell robotic blasting machine

Guyson's RB-RSSA-6 matches the precision and repeatability of robotic motion with the small footprint of a high-performance workcell blasting cabinet.

The 42-inch wide blast chamber of the RB-RSSA-6 houses a single rotary spindle on which an interchangeable component-holding fixture is mounted. Parts are loaded in the blasting machine through an automatic vertical sliding door that is 18 inches in width. A full-depth hinged door on the side of the cabinet provides access for inspection and maintenance. Including the safety-interlocked perimeter enclosure surrounding the robot, the robotic blast machine is 74 inches tall and 72 inches deep.

When the blast cycle is initiated, the load door closes and the component is rotated at controlled and adjustable speed as a single suction-blast gun is directed at target surfaces by the 6-axis robot. Programmed robotic motion of the blasting nozzle ensures that a specific stand-off distance and angle of blast media impingement  is constantly maintained, even as the blast gun manipulator follows the contours of complex-shaped components. The robot also directs a blow-off nozzle during the timed air wash cycle that follows media blasting.

 The rear of the RB-RSSA-6 robotic blast system is sealed by a custom-tailored skirt made of multi-layered laminated fabric. The protective suit fits tightly around the end of the robot arm, yet allows the full range of motion in all axes, as it isolates the precision manipulator from the potentially harsh abrasive environment of the blasting chamber.

The system’s programmable logic controller (PLC), to which the robot controller is slave, is capable of storing and recalling the automated blasting process routines for up to one hundred different components. A custom designed touch-screen interface allows the human operator to select the program for a particular component and also displays process data monitored by electronic sensors, such as spindle RPM, the duration and elapsed time of the blasting cycle and the levels of blast media and contents of the dust collector drum.

Prospective users of robotic blasting equipment are encouraged to submit sample components for free laboratory testing and application engineering evaluation at Guyson’s factory in northeastern New York State.

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ROBOTIC GRIT-BLAST MACHINE FINISHES PRECISELY

Published by Guyson on February 10, 2010

Guyson Corporation has introduced a robotic gritblasting system that enables consistent production of a specified finish on a wide variety of complex-shaped components. The Model RB-9 is designed to offer precision and flexibility in critical surface preparation work.

Guyson RB-9 configured as a 7-axis rotary gritblast machine.

Guyson RB-9 configured as a 7-axis rotary gritblast machine.

A six-axis robot with a suitable payload and range of motion serves as a nozzle manipulator when mated with a rotary table blast cabinet having a 48 x 48 x 48-inch work envelope. Rotation of the turntable is powered by a servomotor and controlled as a seventh axis of robotic motion, allowing extremely accurate positioning and movement of the work piece during automated blasting routines. Thus, the RB-9 is capable of constantly maintaining a specific nozzle angle, offset (stand-off distance) and surface speed as it follows the intricate contours of components in execution of the programmed grit blasting process.

The RB-9 can be optionally equipped with a crane slot in the roof of the blast cabinet to facilitate loading and unloading of heavy workpieces by an overhead hoist. Access to the blast enclosure is provided by two full-width doors with abrasion-protected view windows. The entire blasting chamber and turntable are lined with quarter-inch-thick bonded rubber sheeting to resist the abrasive effects of harsh grit media.

Supplied with either suction-blast or pressure-blast media delivery, the Model RB-9 is commonly provided with an enhanced media reclamation system that includes a vibrating screen classifier to separate larger or smaller particles from the blasting grit of the exact mesh size specified for the surface preparation process. The robotic gritblast system can also feature media level sensors and an automatic dispensing hopper to replenish the supply of blasting grit before a low media level could compromise the precision finishing results. The system illustrated also includes a new design of magnetic separator that continuously removes ferrous particles, such as burr material, from the operating media mix.

Guyson RB9 Robotic Gritblast System, composite viewThe RB-9 machine pictured above incorporates a special safety interlock system designed to comply with the purchaser’s internal machine engineering specifications for robotic equipment. A hand-held wand, a foot pedal and door locks on the blast cabinet and robot cage were integrated by Guyson controls engineers in response to the individual customer’s requirements.

Among the human-machine interface configurations offered by Guyson is a freestanding control console with a touch-screen panel. Blast process parameters associated with up to 100 different robotic blasting routines are stored by the system’s programmable logic controller and recalled at a finger’s touch.

Prospective users of robotic grit-blasting or surface preparation systems are encouraged to submit sample components for free laboratory testing  and application engineering evaluation at the Guyson factory in northeastern New York State.

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ROBOTIC SHOT PEENER CHANGES TOOLS

Published by Guyson on January 22, 2010

Guyson Corporation has introduced a robotic shot peening system that changes blast heads to automatically perform multiple peening operations without manual adjustments or other human intervention. So equipped, a single robotic shot peener can do a variety of metallurgical shot peening processes that would otherwise require two or more automated blast machines.

A robotic nozzle manipulator selects from multiple blasting tools.

A robotic nozzle manipulator selects from multiple blasting tools.

The tool-changing robot blast machine features a slotted rack inside the shot peening
chamber, where the blasting tools are stored by the nozzle manipulator when not in use. The
assortment of tools required is determined by the range of components to be shot peened
and the peening process specifications, but may include straight nozzles of different bore
sizes, a lance with an angled nozzle for ID peening, a rotary lance tool for small ID peening
or a blasting tool that delivers a different size of peening shot.

One wall of the 86  x 78  x 78-inch peening cabinet has a large opening fitted with a custom-
tailored protective suit for the articulated 6-axis robotic arm. The laminated fabric seals the rubber-lined blast chamber, which is fabricated from 1/2-inch thick continuously welded steel plate, and isolates the robot from the harsh shot peening environment while accommodating the full range of motion of the robotic nozzle manipulator. 

The shot peening machine is equipped with a 2,200-pound capacity, 65-inch diameter
turntable that is driven by a servomotor and controlled as a seventh axis of robotic motion.
The rotary lance peening nozzle also has a servomotor drive, and rotation of the nozzle is
programmed through the robot controller as an eighth axis.

Critical to compliance with stringent aerospace shot peening specifications, the robotic
nozzle manipulator is capable of repeatably following the contours of complex-shaped
components while constantly and accurately maintaining the correct stand-off distance,
nozzle angle and surface speed required for the precisely controlled cold-working metal
treatment process.

Prospective users of robotic shot peening, blast finishing or surface preparation systems are invited to submit sample components for free laboratory testing and application engineering evaluation at the Guyson factory in northeastern New York State.

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PRESSURE TUMBLE-BLAST MACHINE

Published by Guyson on January 8, 2010

Guyson Corporation has introduced a pressure-blast version of its popular Model T-50 tumble-blast system that offers advantages for certain challenging batch processing applications. The tumble-basket machine is designed for overall blasting of small components.

Model T-50 Tumble-blast system with pressure-blast media delivery.

Model T-50 Tumble-blast system with pressure-blast media delivery.

Direct pressure media delivery is capable of efficiently accelerating shot or grit to higher velocities, imparting more energy to component surfaces. Not only does pressure-blast speed up the cycle time per batch, but it enables the performance of some surface treatment work that could not be accomplished by suction-blast equipment, such as high-intensity shot peening of racing valve springs, peening other high performance springs or small parts, stripping of tough coatings, blast cleaning heavy scale and etching hard materials.

 The T-50 tumble-blast cabinet features a 30-inch diameter basket that is 15 inches deep and has a working capacity of approximately one cubic foot or 75 pounds of components per batch. The rotation speed of the basket is adjustable, so the tumbling action of different components can be optimized. Guyson’s tilted basket design reduces part-on-part impingement that could damage fragile components and generates better circulation of parts in the batch, yielding more thorough coverage, greater uniformity of finish and significantly shorter blast cycle times compared to barrel or endless belt tumble-blast equipment.

 Two pressure-blast nozzles are fed by a 3.5 cubic foot capacity pressure vessel in the T-50P tumble-blast system. The nozzles are mounted on adjustable brackets to allow direction of the blast at the area of the tumbling mass off components where the turning action of the parts is greatest. At the end of the timed blasting cycle, the flow of blast media is turned off, while the rotation of the tumble-basket continues, and a timed air wash blow-off cycle follows to remove dust and residual shot or grit from the components.

 The footprint of the T-50P blast cabinet is 40 x 50 inches (102 x 127 cm). The tumble-blast machine can be optionally provided with a front discharge chute that enables unloading of the basket directly into a tote bin or carrier tray.

 Prospective users of tumble-blast finishing or shot peening equipment are invited to submit sample components for free laboratory testing and application engineering evaluation at the the Guyson factory in northeastern New York State.

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ROBOTIC BLASTING CELL

Published by Guyson on March 20, 2009

Guyson Corporation has expanded its engineering test laboratory with the addition of a robotic blast system to support application development work on customers’ automated blasting projects as well as our new contract finishing and surface preparation services.

Steve Byrnes and Steve Donohue in the Guyson Test Lab

Steve Byrnes and Steve Donohue in the Guyson Test Lab

Steve Byrnes, President of Guyson Corp. of U.S.A. (at right in photo), unveiled the new equipment at an employee orientation event in the finishing job-shop area of Guyson’s 80,000 square foot plant in Saratoga Springs, NY.

“This investment, together with our advanced CAD/CAM-based software for off-line robot motion programming, will extend our lead in supplying engineered-to-order robotic blast systems to manufacturers of medical, aerospace and other components that require the highest degree of precision and repeatability in surface treatment,” Steve Byrnes told the group.

The addition of the robot blasting cell to the test lab enables on-demand demonstration of robotic surface finishing and shot peening processes, as well as measurable results under actual production conditions. As an asset available for certain types of contract finishing work, the robotic blasting cell offers great flexibility, since the programmed process routine for a particular component can be stored, recalled and exactly repeated at any time.

The system combines a rotary table pressure-blast cabinet with a 6-axis robot that manipulates the blast nozzle. Rotation of the turntable can be controlled as a seventh axis of robotic motion. The versatile blast machine makes it possible to constantly maintain a specified offset, angle of impingement and surface speed while exactly following the contours of complex-shaped components.

In his remarks, Steve Donohue (at left in photo), Guyson’s Vice President of Sales and Marketing, stressed the value of the new robotic blasting cell for process development in partnership with customers.

“Many of our customers are in regulated industries or have rigid quality system requirements, for example, shot peening of aerospace components to stringent specifications such as AMS-2432 to meet NADCAP AC-7117 audit criteria, or medical components processed in accordance with FDA guidelines in an ISO-13485 certified operation. A fully functioning robotic blasting cell enables us to assist our partners with blast process validation, the elimination of non-conformities and the achievement of repeatable Six Sigma quality.”

Prospective users of automated and robotic blast systems or contract finishing services were invited to attend Guyson’s Open House on April 28 and April 29 at our North American design and manufacturing facility in northeastern New York State.

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ROTARY SHOT PEENING SYSTEM

Published by Guyson on February 20, 2009

Guyson Corporation has designed and manufactured a rotary indexing spindle-blast machine for metallurgical shot peening of proprietary machine tool components to dramatically increase the service life of the tooling. The suction-blast peening system incorporates special features to control the cold working process and ensure consistent impact treatment results.

RXS-900 Rotary Shot Peening SystemThe six-station rotary table of the automated blast machine is mounted on a precision cam indexer that accurately steps the fixtured components through isolation, peening and blow-off chambers within the abrasion-protected cabinet. At two shot peening stations in the blast enclosure, the component-bearing spindles are rotated at controlled speed during the timed process cycle. The spindle rotation speed is adjustable.

Multiple blast guns are pre-arranged at the shot peening stations, rigidly held in position on telescoping and adjustable brackets, so the correct angle and offset of each nozzle is maintained to ensure the impingement of shot on target component surfaces. To simplify shot peening of similar components that vary in height or diameter, the blast guns are affixed to a ballscrew-ballnut linear actuator at each peening station. The position, stroke and speed of nozzle motion is programmable and synchronized with component rotation.

Many peening system features, especially the configuration of the controls and associated electronic monitoring and regulating capabilities, are largely dictated by the shot peening specification to be met, whether an OEM’s internal process spec or aerospace material specs such as AMS-2430, AMS-2432 or AMS-S-13165. In any case, one of the key elements is to maintain strict control over shot sizing, a critical factor in ensuring the uniformity of the compressive stresses induced in the shot peening process. Shot size control is accomplished by the addition of a vibrating screen classier in the media reclamation system to remove over- and under-sized shot.

Shot peening process control technologies that can be incorporated in the automated system include shot flow monitors, closed-loop blast pressure and shot flow control, facilities to maintain peening shot sphericity, shot supply level sensing and automatic replenishment, plus enhancements to the human-machine interface (HMI) and central microprocessor to support data acquisition and logging of process parameters for statistical trending and documentation purposes.

Prospective users of automated blast finishing or shot peening systems are encouraged to submit sample components for free laboratory testing and application engineering evaluation at Guyson’s design and manufacturing center in northeastern New York State.

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WORK CELL BEAD BLASTING MACHINE

Published by Guyson on November 26, 2008

Guyson Corporation has expanded its line-up of automated blasting systems with small-footprint models designed to meet the special requirements of cell-based production. The RSSA-6 rotary blast machine is adaptable for various purposes, such as deburring, cosmetic finishing and technical surface preparation.

Guyson RSSA-6 Bead Blasting System

Guyson RSSA-6 Bead Blasting System

The single spindle or table of the Model RSSA-6 is fitted with a component-holding fixture that is easily changeable for processing of different parts. As the component rotates at controlled and adjustable speed, it is exposed to the timed blast from up to four suction-feed blast guns affixed to telescoping brackets that allow each nozzle to be positioned at the correct angle and offset for coverage of target surfaces.

Motion of the blast guns enables automated processing of components of varying length without adding more guns. A ball screw and ball nut linear actuator enables the speed and stroke of the traversing gun movements to be programmed and accurately synchronized with component rotation to ensure complete and even coverage. Once all process parameters are set for a particular component, the RSSA-6 will repeat the cycle identically, producing highly consistent finishing results. If desired, dimensional data and process routines for different components can be stored by the system’s programmable logic controller (PLC) and recalled on demand.

The overall width of the RSSA-6 blast cabinet is 52 inches, and it is 32 inches in depth (132 x 81 cm). Several loading door configurations are available, including a vertical sliding door actuated by a pneumatic cylinder. A full-depth hinged side door with safety interlocks provides access to the blast chamber for inspection, adjustment and maintenance.

Engineered-to-order, the finishing system is supplied with a suitably sized media reclaimer and cyclone separator, as well as a cartridge-type, reverse pulse dust collector with an extraction capacity of 1000 cubic feet of air per minute. The media delivery system can be enhanced by an electronic sensor-activated replenisher that automatically adds shot or grit when a low media level is detected. Guyson also offers a comprehensive package of abrasion resistance features, such as rubber cabinet lining and cast urethane ducting, when aggressive blast media are to be used in the blast system.

Prospective users of automated blasting equipment are encouraged to submit sample components for free laboratory testing and application engineering evaluation at Guyson’s design and manufacturing center in northeastern New York State.

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AFFORDABLE INDUSTRIAL PRESSURE-BLAST CABINET

Published by Guyson on August 26, 2008

Guyson Corporation has introduced a more compact and economical direct pressure media delivery module available on several sizes of industrial manual cabinets. The Model 8-EP is the largest blast cabinet to be fitted with the novel pressure-blast system.

Guyson Model 8 with economy pressure-blast module

Guyson Model 8 with economy pressure-blast module

Pressure-blast media delivery is preferred for processing of components with a large amount of surface area and for surface treatment operations such as descaling, etching, coating removal and surface preparation that may require greater kinetic energy. Because the Model 8-EP’s direct pressure blasting system accelerates media throughout the length of the blast hose, it is capable of delivering media particles at much higher velocities than suction-blast equipment operated at the same blast pressure. Industrial blast cabinet users report that pressure-blast usually proves to be at least four times faster than suction-blast.

Consisting of a cyclonic separator linked to an A.S.M.E.-certified pressure vessel, the pressure-blast module is attached to the rear of the blast cabinet. The standard pressure vessel holds approximately 0.8 cubic foot (22.6 liters) of media.The separator/media reclaimer removes dust from the recirculated blast media and is powered by a freestanding cartridge-type dust collector with an air extraction capacity of 500 cubic feet per minute (14 m3/min.). Flexible ducting connects the dust collector to the cyclonic separator, allowing the collector to be positioned wherever it is most convenient.

The blast chamber of the Model 8-EP is 36 inches high at the rear of the sloped cabinet,42 inches wide and 42 inches deep (914 H x 1066 W x 1066 mm D). Open access to the finishing chamber is provided by side- and top-hinged doors at the front, to simplify loading of bulky work pieces, as well as a convenient side-hinged, slam-shut door on one side. The cabinet is optionally equipped with a rubber-flapped crane slot in the roof of the blast enclosure, above the side door, to facilitate loading and unloading of heavy components by an overhead hoist or crane.

Most types of dry blast media can be used in the Model 8-EP pressure-blast cabinet, including plastic grit, glass beads and fast-cutting mineral grit, such as aluminum oxide, giving the system great versatility for a wide range of blasting applications. When harsh abrasive media are to be used, the cabinet is supplied with protective features that include rubber lining of the blast chamber, a wear resistant boron carbide blast nozzle and a sacrificial inner abrasion window mounted in a quick-change frame to prevent accidental frosting of the safety-glass viewing window.

Prospective users of industrial cabinet-blast equipment are encouraged to submit sample components for free laboratory testing and application engineering evaluation at the Guyson factory in northeastern New York State.

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