CRYOGENIC MEDIA-BLASTING DEBURRING Media-blasting and drum deburring systems and washing systems for die-cast metal, rubber and plastic components mewo-machines.com mewo-wacker.de
Maschinenfabrik Erwin Wacker Olpe We have been manufacturing equipment, developing technology and supplying proven customerspecific specialist solutions since 1948. Customers around the world use our products for the cryogenic treatment of seals and moulded parts. We are a family-run company, and maximum benefit for our customers is always our first priority. The processes we develop have only one objective: to increase and sustainably ensure the competitiveness of our customers with the highest quality and outstanding precision. Your specialist for Cryogenic deburring systems Media-blasting deburring systems Drum deburring systems Washing systems Custom-built solutions Handling systems Rubber Plastics Die-cast metal 2
Machine overview Machine Applications Page ROTOR TS 7/TS 7.12 High-performance compact machines for various cryogenic deburring applications of seals and moulded parts made of elastomer, plastic and non-ferrous die-cast metal 4 WTS 7.12 Compact, high-performance processing centre that meets the highest standard of cryogenic deburring with subsequent cleaning or surface treatment 6 JET ROTOR.2 Back-to-basics drum-type media-blasting deburring machine, ideal as an introduction to cryogenic finishing of elastomeric, plastic and non-ferrous die-cast metal moulded parts in small to medium-sized batches. Load volume up to 20 litres. 8 ROTOR TSE 20/40/60 Drum-type media-blasting deburring systems for the cryogenic finishing of large batches of tumbler-compatible elastomeric, plastic and non-ferrous die-cast metal moulded parts 10 TRS 100/350/700 Drum-type deburring machines for the cryogenic finishing of plastic or elastomeric moulded parts with a sensitive surface 12 WTT 30/50 Washing systems for the fine deburring and cleaning of rubber, plastic and non-ferrous die-cast metal moulded parts 14 3
ROTOR TS 7/TS 7.12 The ROTOR TS 7 and TS 7.12 models are high-performance compact media-blasting machines for a wide variety of deburring applications of seals and moulded parts made of elastomer, plastic and non-ferrous die-cast metal. ROTOR TS 7 ROTOR TS 7.12 These compact machines with a load volume of max. 7 litres (TS 7) or 12 litres (TS 7.12) guarantee extremely precise results with everything from laboratory prototypes requiring occasional reworking to large-scale, multi-shift production runs of bulk goods, as well as individually inserted moulded parts with article-specific feeds. The small media-blasting chamber keeps deburring times short, combining high efficiency with low nitrogen consumption. The removable basket (quick-change basket system) allows the next basket to be filled while deburring is in progress, thus eliminating downtime. A double cyclone ensures dedusting of the blasting chamber and extraction of the used nitrogen gas. The modern SPS control unit Siemens S7, CPU 315 2PN/DP enables many data sets to be stored, thus guaranteeing the reproducibility of all important process parameters; these can also be retrieved as a CSV file via the optional USB interface and transferred to your ERP system for evaluation. The blasting medium used is plastic granulate; as an optional extra, both systems can be adapted to work with steel shot in case of extreme deburring requirements. Controlled blasting medium feed, exact temperature regulation and two-way blasting during every cycle guarantee exact, high-precision reproducibility of results in all areas of the processing basket. 4
Advantages Noise level 80 db Low space requirement Precise temperature control Low consumption of nitrogen The most modern control technology Option Steel shot mode Barcode scanner USB interface SD card 3.1 certificate Technical data Centrifuge n 1 Granulate spiral n 2 Liquid nitrogen N2 Deburring space n 3 TS 7 TS 7.12 Centrifuge speed 1000 8500 1/min. 1000 9500 1/min. Batch volume 1 7 litres 1 12 litres Working temperature to -150 C to -150 C Drum speed 8 46 1/min. 8 46 1/min. Control Article data memory 2000 articles alphanumerical 2000 articles alphanumerical Acoustic level 80 db 83 db Required power 4.5 kw 4.5 kw Weight 350 kg 370 kg Dimensions machine W 1250 x H 1820 x T 1260 mm W 1400 x H 1870 x T 1260 mm Control panel/control box 800 x 520 mm 800 x 520 mm 5
WTS 7.12 The WTS 7.12 model is a compact high-performance processing centre that meets the highest standard of cryogenic deburring with subsequent cleaning or surface treatment. Suitable for a wide range of applications from extremely small seals and precision components to sturdy moulded parts made of elastomer, plastic or non-ferrous die-cast metal of any size from 1.0 mm to approx. 400 mm. High-precision processing of one-off prototypes to medium-size serial production runs with load volumes between 1 and 12 litres. Items for deburring can be bulk goods or individually secured inserted moulded parts, depending on individual requirements. The WTS 7.12 consists of a compact steel cryogenic deburring chamber and a high-pressure cleaning and drying unit. Removable loading baskets or feed systems (replaceable basket system) allow the next basket to be filled while deburring is in progress, thus eliminating downtime. Controlled blasting medium feed, exact temperature regulation and blasting from both sides during every cycle guarantee the efficient, high-precision reproducibility of results in all areas of the processing basket. Connected cyclones ensure internal dedusting. When deburring has been completed, the processing baskets can be transferred directly to the cleaning unit without handling the moulded parts, which can be washed with/without high pressure and with/without additional detergent, then immediately dried. The air used for drying is extracted via a multi-stage filter to preserve the level of cleanliness achieved during the washing process. The modern SPS control unit Siemens S7, CPU 315 2PN/DP enables many data sets to be stored and guarantees the reproducibility of all important process parameters for every individual step or for the entire process; the data including a comparison of nominal and actual values can either be retrieved manually via a USB stick, or connected directly to your LAN network via the existing Ethernet interface. The blasting medium used is plastic granulate; as an optional extra, the integrated blasting system can be adapted to work with steel shot in case of extreme deburring requirements. 6
Advantages Noise level 80 db Low space requirement Precise temperature control Low consumption of nitrogen The most modern control technology Option Steel shot mode Barcode scanner USB interface Ethernet interface SD card 3.1 certificate Technical data WTS 7.12 WTS 7.12 Blasting unit Washing unit Centrifuge speed 1000 9500 1/min. Batch volume 1 12 litres 1 12 litres Working temperature Operating temperature for blasting up to -150 C Operating temperature for washing up to 60 C Washing pressure 50 200 bar Dry air temperature to 90 C Drum speed 8 46 1/min. 8 46 1/min. Acoustic level 83 db 70 db Control Article data memory 2000 articles alphanumerical Required power Weight Dimensions machine Control panel/control box 14.5 kw 730 kg* W 3100 x H 1920 x T 1750 mm integrated * varies according to version 7
JET ROTOR.2 The JET ROTOR.2 is a basic drum-type media-blasting deburring machine that is ideal as an introduction to cryogenic finishing of elastomeric, plastic and non-ferrous die-cast metal moulded parts in small to medium-sized batches and a load volume up to 20 litres. The machine requires very little floor space thanks to its extremely compact construction, and the well insulated cryogenic cell is made entirely of welded stainless steel, ensuring that nitrogen consumption is kept low. While coarse burrs are separated from the granulate in the deburring drum, the blasting media is dedusted by an external cyclone. The modern SPS control unit (Siemens S7-300; CPU 315 2PN/ DP) enables many data sets to be stored and guarantees the reproducibility of all important process parameters. 8
Advantages Noise level 80 db Low space requirement Brief time for granulate replacement Low consumption of nitrogen The most modern control technology Option Charging belt Emptying riddle screen Parameter readout printer Barcode scanner USB interface for batch protocol Patents German patent DE 10 2005 040 420 B4 German utility patent DE 20 2005 021 912 U1 Technical data Centrifuge Nitrogen supply Drum guide Granulate spiral conveyor Blasting drum, rotating Drive Granulate basket JET ROTOR.2 Centrifuge speed Batch volume 1000 9500 1/min. 1 20 litres Working temperature for blasting to -150 C Granulate material throughput Drum speed Control Article data memory Acoustic level Required power Weight Dimensions machine Control panel/control box to 1.5 tons/h 5 30 1/min. 2000 articles alphanumerical 80 db 14 kw 1100 kg* W 2900 x H 2100 x T 2400 mm integrated * varies according to version 9
ROTOR TSE 20/40/60 The drum-type media-blasting deburring machines from the ROTOR TSE series are designed for cryogenic finishing of large batches of tumbler-compatible elastomeric, plastic and non-ferrous die-cast metal moulded parts. ROTOR TSE 20/40 Standard ROTOR TSE 60 Fully automatic Precise temperature control enables even the most complex moulded parts and seals to be deburred. Load volumes from 1 30 litres (TSE 20), 50 litres (TSE 40) and up to 100 litres (TSE 60). The well insulated cryogenic cell made entirely of welded stainless steel, the compact media-blasting chamber and short processing times guarantee low nitrogen consumption. In addition, the external dust removal system sucks the cold gas back into the cryogenic cell, which prevents significant cryogenic losses. The conventional refrigeration unit dehumidifies and cools when the machine is not running. Large inspection doors facilitate cleaning and maintenance work. Internal screening of the blasting media ensures the separation of the removed burrs and dust from the granulate material, as well as guaranteeing the purity and cleanliness of the blasting shot. The modern SPS control unit (Siemens S7-300; CPU 315 2PN/DP) enables up to 2000 sets of data to be stored and guarantees the reproducibility of all important process parameters. As an optional feature, all process data can be read out via the integrated Ethernet interface and transferred directly to your in-house LAN for further processing and analysis. Plastic granulate is used as a blasting medium; as an optional extra, steel shot can also be used in case of extreme deburring requirements. 10
Advantages Noise level 80 db Low space requirement Large loads Short batch times Precise temperature control The most modern control technology Granulate volume dosing Low nitrogen consumption Option Automatic feed unit Emptying riddle screen Parameter readout printer Barcode scanner USB interface for batch protocol Ethernet interface for LAN connection Granulate circuit monitoring system Steel shot mode Patents German patent DE 10 2005 040 420 B4 German utility patent DE 20 2005 021 912 U1 European patent application EP 2 481 524 A1 German utility patent DE 20 2011 002 098 U1 Technical data Nitrogen supply Blasting drum (rotating) Granulate spiral-conveyor (diagonally) Drum guide Granulate basket Drive Centrifuge Internal riddle screen Granulate spiral-conveyor (vertical) TSE 20 TSE 40 TSE 60 Centrifuge speed 1000 9500 1/min. 1000 9500 1/min. 1000 9500 1/min. Batch volume 1 30 litres 1 50 litres 1 100 litres Working temperature for blasting to -150 C to -150 C to -150 C Granulate material throughput to 1.5 tons/h to 1.5 tons/h to 1.5 tons/h Drum speed 5 30 1/min. 5 30 1/min. 5 30 1/min. Control Article data memory 2000 articles alphanumerical 2000 articles alphanumerical 2000 articles alphanumerical Acoustic level 80 db 80 db 80 db Required power 12 kw 14 kw 25 kw Weight 1800 kg* 2300 kg* 3200 kg* Dimensions machine W 3700 x H 2150 x T 2650 mm W 3700 x H 2450** x T 4400 mm W 3700 x H 3000** x T 5150 mm Control panel/control box integrated integrated 1200* x 500* x 2000 mm * Varies according to version ** Height when automatic door is open 11
TRS 100/350/700 TRS 100/350/700 is a drum-type deburring machine for the cryogenic finishing of plastic or elastomer moulded parts with sensitive shapes, materials or surfaces. The TRS series was designed to provide an alternative to media-blasting deburring for special applications that involve moulded parts with sensitive surfaces or high fragility. Dependent on the individual application and requirements, the machine operates with the patented MEWO process supported by special additives. As the unit requires little floor space, it can be installed in confined production lines (internal cell production). The N 2 exhaust gas is expelled via a dedusting cyclone with non-return valve, thus preventing significant cryogenic losses and negative influences through heat or moisture. The modern control unit enables many sets of data to be stored and guarantees the reproducibility of all important process parameters. The well insulated cryogenic cell, compact drum and short processing cycles ensure that nitrogen consumption remains low. 12
Advantages Operation possible with or without additive Automatic charging and emptying possible Deburring supported by diagonally mounted tumbling bars Clean separation ofthe workpiece from burr Low space requirement Option Exact temperature control Low nitrogen consumption The most modern control technology Printout of parameters possible Short batch times Machine constructed 100 % of stainless steel Internal separation by means of perforated drum Patents German patent application DE 199 06 915 A1 Technical data N2 Temperature sensor Exhaust pipe Drive Charging door Abrasion Draining door for abrasion on the back side TRS 100 TRS 350 TRS 700 Drum volume 100 litres 350 litres 700 litres Working temperature Strahlen to -150 C to -150 C to -150 C Drum speed 10 35 1/min. 10 35 1/min. 10 35 1/min. Control Siemens S7, CPU 315 2DP, 8 Touchpanel MP 277 Siemens S7, CPU 315 2DP, 8 Touchpanel MP 277 Siemens S7, CPU 315 2DP, 8 Touchpanel MP 277 Article data memory 2000 articles alphanumerical 2000 articles alphanumerical 2000 articles alphanumerical Required power 6 kw 12 kw 20 kw Weight 850 kg 1000 kg 1300 kg Dimensions machine W 2300 x H 2000 x T 1500 mm W 2500 x H 3150** x T 2100 mm W 3400 x H 3950** x T 2500 mm Control panel/control box 800 x 250 mm or 1250 x 500 x 2000 mm* 800 x 250 mm or 1250 x 500 x 2000 mm* 800 x 250 mm or 1250 x 500 x 2000 mm* * Varies according to version ** Height when automatic door is open 13
WTT 30/50 Washing systems for the cleaning and final deburring of moulded parts made of rubber, plastic and non-ferrous die-cast metal. WTT 30 and WTT 50 were designed as continuous-flow, high-performance washing systems for the final deburring, cleaning and drying of rubber, plastic and non-ferrous die-cast metal moulded parts. In both systems, the cleaning process is performed in a rotating drum either with or without high pressure and with or without the addition of detergent, which can be administered in precise doses by the control unit. In order to prevent the inadvertent mixing of parts, extremely small items can be processed in a closed basket that can be inserted and removed separately. The purity level achieved during the cleaning process is subsequently maintained by a multi-stage filter system mounted downstream of the air intake for the dryer. The patented inclination of the machine body enables the ergonomic charging and discharging of the system, as well as the optimised tumbling of the moulded parts during the individual stages of the washing and drying processes. The modern SPS control unit (Siemens S7-300; CPU 315 2PN/ DP) ensures that many sets of data and cleaning programmes can be stored and guarantees the reproducibility of all important process parameters and a constant level of cleanliness. 14
Advantages High-efficiency cleaning effect Multiple washing stages Easy handling Low consumption of water The most modern control technology Low space requirement Option USB interface for batch protocol Barcode scanner Separate removable basket for small parts Assisted emptying of the processed material Ethernet interface for LAN connection Waste water filter with fast-clean system Adapter for TS 7.12 blasting basket (WTT 50 only) Patents German patent application DE 10 2007 018 111 A1 Technical data Exhaust air For washing and emptying machine is slewable Hot-air drying High-pressure washing (oscillating blast pipe) Washing drum, rotating Water supply High-pressure water pump (200 bar) WTT 30 WTT 50 Batch volume 40 litres 70 litres Water temperature to 60 C to 60 C Waschdruck 50 200 bar 50 200 bar Dry air temperature to 90 C to 90 C Drum speed 5 30 1/min. 5 30 1/min. Control Article data memory 2000 articles alphanumerical 2000 articles alphanumerical Acoustic level 78 db 80 db Required power 25 kw 25 kw Weight 800 kg 900 kg Dimensions machine W 1400 x H 2200 x T 1700 mm W 1400 x H 2250 x T 1900 mm Control panel/control box integrated integrated 15
MEWO GmbH & Co. KG Bilsteiner Strasse 12 D-57462 Olpe Phone: +49 (0) 2761 / 9453-0 Fax: +49 (0) 2761 / 9453-29 E-mail: kontakt@mewo-machines.com mewo-machines.com