Special Automation Spotlight # 3539 MARKETING DATA SPECIFICATIONS

INDUSTRY:
Stainless steel tube manufacturing.
APPLICATION:
De-scaling the ID of various sized tubes of varying lengths. From 1/8" ID to 2" ID and from 8 feet to 40 feet long.
EQUIPMENT SOLUTION:
ZERO worked closely with the customer developing a system which included two pressure blast machines; a 1/2 cu ft machine to clean 5 small ID tubes at a time, and a 6 cu ft machine with a 60-degree bottom for high production cleaning. The rest of the solution involved workpiece handling using a special 40 foot long track with nylon guide rollers which can accommodate tubes ranging from 8 feet to 40 feet in length and media recovery and reclaim which incorporates a 4 foot by 4 foot by five and one-half foot sealed cabinet, a 900 cfm reclaimer and a 900 cfm reverse-pulse dust collector.
PART HANDLING:
The operator loads bundles of tubes onto one of two tube staging racks, (depending on the tube length). Five tubes at a time are placed on a 40 foot long track equipped with nylon guide rollers.
ADVANTAGES & SELLING FEATURES:
The customer was able to achieve uniform cleaning, media reclaiming and reuse with an increased production rate.
SPECIAL OPTIONS:
Sealed blast cabinet into which scale and spent media exit from the tubes being cleaned. Special pre-blast cleaning staging racks. Programmable blast nozzle carriage with attached control panel.
CABINET SIZE:
4 foot by 4 foot by 5.5 foot closed cabinet into which the ends of the tubes are inserted
MEDIA:
Aluminum oxide
BLAST GUNS/NOZZLES:
Special adaptors allow efficient programmable cleaning of varying tube IDs.
RECLAIMER:
900 cfm (rubber lined)
DUST COLLECTOR:
RPH-2L, 900 cfm


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Special Automation Spotlight # 1709 MARKETING DATA SPECIFICATIONS

INDUSTRY:
Mining equipment manufacturer.
APPLICATION:
Clean ID of hydraulic piston cylinder forgings prior to final assembly.
EQUIPMENT SOLUTION:
ZERO built a special automated blast cabinet from 12-gauge steel and installed a heavy-duty track and a powered turntable to support the extraordinarily heavy (up to 3,000 pounds) workpieces.
PART HANDLING:
The heavy workpieces are moved by gantry cranes to the cabinet's worktable. Centering pins correctly position the piece, once in the cabinet, a pin locks the center of the turntable to align with the oscillating arm. The system is started and automatically performs the blast and blow-off cycles allowing the operator to stage the next part.
ADVANTAGES & SELLING FEATURES:
The customer was getting acceptable results blasting with steel grit but was using a dedicated operator to manually blast the parts. Switching to an automated system sped up production and reduced labor. The single biggest selling feature was this system's success in freeing the operator to perform other tasks. The versatile controller handles an assortment of parts with little operator setup. The cabinet's robust construction stands up to high-production requirements using steel grit.
SPECIAL OPTIONS:
The programmable controls adjust the vertical oscillator's stroke length and rate to process a variety of parts without adjusting nozzles or fixtures
CABINET SIZE:
Special cabinet - 5 ft by 5 ft by 10 ft tall, constructed from 12-gauge steel.
MEDIA:
Steel grit
BLAST GUNS/NOZZLES:
One CAM 3 nozzle to clean ID of cylinder in a single pass. Additional nozzle for manual touch-up and processing other parts.
RECLAIMER:
A bucket elevator feeds the steel grit into an air-wash abrasive cleaner.
DUST COLLECTOR:
RPH 3L - 1,200-cfm reverse-pulse collector with 3 cartridges pulls air from the enclosure and powers the air-wash media cleaner.

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Special Automation Spotlight # 2321 MARKETING DATA SPECIFICATIONS

INDUSTRY:
Abrasive belts, disks, paper, mfg.
APPLICATION:
Edge cleaning of coating to prepare for belt seam bonding.
EQUIPMENT SOLUTION:
  • Specialized belt conveyor consisting of a timing belt conveyor for drive.
  • Urethane belt conveyor for masking the edge of the paper.

PART HANDLING:
Pinch belt conveyor
ADVANTAGES & SELLING FEATURES:
  • Multi-operation system provides for loading, blasting, inspection, reblasting, adhesive application and unloading.
  • Video inspection station offers improved process efficiency (camera and monitor provided by customer).
  • Second blast station operates only when required.

SPECIAL OPTIONS:
4 position backstop adjustment in load area provides 4 blast widths. Produced parts in accordance with +/- 3/16" blast width tolerance. Allen Bradley SLC 503 controller with panel view touch screen for programming.
CABINET SIZE:
4' long load station
4' long clamp station
4' W x 4' D x 5.5' H 1st blast station
4' W x 4' D x 5.5' H inspection station
4' W x 4' D x 5.5' H 2nd blast station
4' long adhesive application station
4' long unload area
MEDIA:
Glass bead
BLAST GUNS/NOZZLES:
#6 Boron Carbide - 10 nozzles in first cabinet and 2 nozzles in second cabinet
RECLAIMER:
2500 CFM
DUST COLLECTOR:
RPH-6L

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Special Automation Spotlight # 4225 MARKETING DATA SPECIFICATIONS

INDUSTRY:
Industrial refrigeration equipment manufacturer.
APPLICATION:
Cleaning the interior and exterior of medium to large diameter steel pipe (from 6 to 30 inches diameter, up to 12-1/2 feet long).
EQUIPMENT SOLUTION:
Sample processing showed that the mill scale and contaminants were loosely adhering so suction blasting with aggressive aluminum oxide media could efficiently clean the parts and meet production requirements. The versatile ZERO cabinet simultaneously blasts the OD and ID of the pipe. Manually repositioning the blast guns readies the cabinet to handle different diameter parts.
PART HANDLING:
Employees manually roll pipe from the transport table into the machine. The pipe rotates on twin drive shafts fitted with closely spaced urethane wheels to prevent marring. A programmable logic controller stores parameters for up to 12 parts and adjusts the rotation speed, blast duration, and blast gun travel rate accordingly.
ADVANTAGES & SELLING FEATURES:
  • Replacement of chemical process and airless blasting to eliminate maintenance, exposure liability, and chemical bath disposal costs.
  • This one ZERO cabinet replaced an acid bath (and its associated hazards) and an airless blast machine. It greatly reduced the amount of welding rework caused by improper cleaning and eliminated a production bottleneck.

SPECIAL OPTIONS:
  • External track and lance system propels internal and external blast gun arrays through the cabinet.
  • Dual vertical-lift pneumatic doors open the length of the cabinet for part loading and removal.
CABINET SIZE:
Custom enclosure - 14'W X 4'D X 6'H
MEDIA:
Aluminum oxide
BLAST GUNS/NOZZLES:
10 ZERO automatic blast guns with #6 wide-spray nozzles.
RECLAIMER:
3,600-cfm pull-through cyclone separator, with rubber lining to resist wear from aluminum oxide.
DUST COLLECTOR:
RPH 8L - 3,600-cfm reverse pulse collector with eight cartridges.

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Special Automation Spotlight # 2999 MARKETING DATA SPECIFICATIONS

INDUSTRY:
Specialty tube manufacturer.
APPLICATION:
Cleaning ID of straight tubes ranging from 1/16 inch to 7/8 inch and varying from 5 to 40 feet in length.
EQUIPMENT SOLUTION:
Pressure blast nozzle attaches to one end of tube. Other end points into cabinet where multiple deflector plates knock media into vacuum recovery hopper.
PART HANDLING:
Tilted rack holds tube prior to blasting. Molded urethane rollers align the tube between the nozzle and cabinet.
ADVANTAGES & SELLING FEATURES:
  • Special blast head with tungsten carbide inserts allows quick changeover for different diameter tubes.
  • Blast head glides along track to adjust to length of tube.

SPECIAL OPTIONS:
  • Blast head holds specially made tungsten carbide inserts, sized to the ID of the tubes.
  • Control panel mounted with blast head to keep start and stop functions at operator's fingertips.
  • Dual blast machines - one for tubes and one for nozzle inserts 3/32" to 3/8".
CABINET SIZE:
4'W X 4'D X 5'H. Tracks measure 40 feet in length.
MEDIA:
Aluminum oxide 100 to 400 mesh.
BLAST GUNS/NOZZLES:
Blast head with special tungsten carbide nozzle inserts.
RECLAIMER:
900 cfm (rubber-lined)
DUST COLLECTOR:
RPH-2L, 900 cfm

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Special Automation Spotlight # 4251 MARKETING DATA SPECIFICATIONS

INDUSTRY:
Office Products Equipment
APPLICATION:
Etch aluminum copier rolls to accept coatings.
EQUIPMENT SOLUTION:
Special cabinet with precisely aligned drive shafts to mask and rotate parts during blasting.
PART HANDLING:
Two track-mounted parts handling carts to insert and remove copier rollers through pneumatic doors. Carts feature PLC controlled arm to position roller. Rollers are held for blasting by combination masking fixture and parts rotation drive.
ADVANTAGES & SELLING FEATURES:
Exceeds customer expectation for production rate, and consistency of finished parts.
This is the second-generation ZERO automated machine purchased by this customer to process rolls.
SPECIAL OPTIONS:
Programmable Logic Controller integrates multi-step parts handling mechanisms, precisely placing, rotating and removing copier rolls without marring blasted surfaces.
Integrated sensors and proximity switches activate parts handling cycle only when parts are properly positioned on carts.
Clear vinyl skirting on media recycling stand and dust collector helps contain extraneous dust and reduce noise levels.
Multi-stage warning lights signal system start-up.
CABINET SIZE:
4' x 4' x 6' with track extensions for parts handling carts. Rugged, externally mounted chain drive handles part rotation. Ball & screw conveyer ensures smooth, precise movement of gun array traversing parts.
MEDIA:
Aluminum oxide
BLAST GUNS/NOZZLES:
Four #6 wide spray boron carbide suction blast guns and one de-ionizing gun mounted on gun array to minimize dust contamination of rollers.
RECLAIMER:
1,200-cfm cyclone separator, with vibratory classification and magnetic particle separator.
DUST COLLECTOR:
RPH 3L - 1,200-cfm reverse pulse collector with three cartridges.

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Special Automation Spotlight # 4620 MARKETING DATA SPECIFICATIONS

INDUSTRY:
Ground Turbine Operators and Repair Companies
APPLICATION:
Remove heat-resistant coating from inside the ground turbine’s exhaust transitions and baskets for inspection and repair.
EQUIPMENT SOLUTION:
BNP 720 pressure blast cabinet with heavy-duty track, work car, and turntable, modified with an oscillating, rotating lance using a CAM nozzle. A manual nozzle is also available
PART HANDLING:
Operator loads part onto a fixture fitted to a turntable mounted on the workcar. The workcar is moved into the cabinet.
ADVANTAGES & SELLING FEATURES:
Blast times are cut by one-fourth. The automated system allows the operator to stage the next part or work on other tasks.
SPECIAL OPTIONS:
Depending on media selected, the cabinet can simply etch the surface of a new part to accept the heat-resistant coating or remove old coatings from parts for inspection.
CABINET SIZE:
BNP 720 with special automation
MEDIA:
Aluminum Oxide
BLAST GUNS/NOZZLES:
One CAM X multi-outlet nozzle and one manual pressure blast nozzle.
RECLAIMER:
1,200-cfm reclaimer with alox kit.
DUST COLLECTOR:
RPH 3L - 1,200-cfm

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Special Automation Spotlight # 1154 MARKETING DATA SPECIFICATIONS

INDUSTRY:
NASA Space Shuttle Program subcontractor
APPLICATION:
Complete cleaning of spent solid rocket motor casings, and preparing of new casings before they are charged with fuel.
EQUIPMENT SOLUTION:
Aerolyte blast room using a fully articulated boom with computer-controlled, multiple blast nozzle cleaning system. Full-floor M-Section pneumatic recovery modules with load rated 2,000 lb. per square foot grating.
PART HANDLING:
The rocket motor components ride on the customer’s existing work cars, which lock in place to ensure proper position relative to the computer’s mapping system.
ADVANTAGES & SELLING FEATURES:
Precisely programmed computer controls and sensors protect these complex, expensive parts from damage.
Clemco integrated the customer’s part handling controls to work with the blast system controls.
SPECIAL OPTIONS:
Except for blast hoses and nozzles, every mechanical component of the articulated boom was designed and built specifically for this application.
To ensure smooth boom movements, the articulated arm uses “Serapid” rigid chain technology. Computer controls and programming by Clemco includes several levels of crash protection to protect rocket motors and boom from accidental contact.
CABINET SIZE:
Column-bolt blast enclosure — 21' by 20' by 19' high. Includes 100 candle foot lighting, view windows, and structural reinforcements to support boom.
MEDIA:
?
BLAST GUNS/NOZZLES:
Five tungsten carbide nozzles - 1/2 inch orifice. Three nozzles are powered by a dual-chamber pressure vessel filled with virgin media only. Two nozzles apply recycled media from a second dual-chamber vessel.
RECLAIMER:
5,000-cfm cyclone separator, plus 30-inch vibratory screen separator.
DUST COLLECTOR:
Reverse pulse collector specified by customer.

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Special Automation Spotlight # 7494 MARKETING DATA SPECIFICATIONS

INDUSTRY:
Gasket Mfg.
APPLICATION:
Clean masked areas of auto engine head gaskets.
EQUIPMENT SOLUTION:
Pass-through belt conveyor with magnet under belt to hold mask to gasket as it passes through blast station.
PART HANDLING:
Magnetic belt conveyor
ADVANTAGES & SELLING FEATURES:
  • Magnetic Conveyor
  • Sensors signal presence of parts as they enter the entrance vestibule setting timer which tracks the travel of the part from sensor to blast station
  • Special safety interlock switches on the reclaim access door

SPECIAL OPTIONS:
85 dBA noise level requirement. Special safety interlock switches per customer specification installed on the reclaim access door. Sensors detect the presence of a part as it enters the entrance vestibule. The sensor triggers a timer set to the time it takes for a part to travel from the sensor to the entrance of the blast station. (Sensor is out of the blast area.)
CABINET SIZE:
4'W X 4'D X 5.5'H blast cabinet
MEDIA:
20/30 Urea Plastic Media
BLAST GUNS/NOZZLES:
(6) #6 Tungsten Carbide
RECLAIMER:
1200 cfm
DUST COLLECTOR:
RPH - 3L, 1200 cfm

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