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The function of a tunnel shot blast machine is to uniformly clean the surfaces of workpieces, while the structure and operating principle are rather simple. To begin with, let us quickly summarize how a tunnel shot blast machine functions. In a nutshell, the steel shots are ejected at a high velocity onto the surface of the workpieces by the turbine windmills after they have been aired and stored by the air-blower and bucket elevators. The entire process of surface cleaning and preparation takes place inside a blast chamber.
There are several types of tunnel shot blast machines:
All the machines above are explained in figures in the description of the entire machine's working principle. Another easy way to know more about them is to search for videos online.
Production Capacity:
The amount of media blasted per time or hour period, typically in tons or cubic feet. For example, a 16-foot tunnel may have a capacity of 8 tons/hour.
Media Recycling System:
Whether it automatically separates, collects, and reuses spent blasting media or does so manually. Some tunnels may have an air classifier that does this efficiently from the media hopper.
Tape/Masking Automation:
How much of the process and afterward is automated. Are there only a few manual stages? If a large number of parts are blasted, a tunnel machine usually has more automation, and parts are blasted more efficiently and with less interference.
Energy/Electricity:
The amount and kind used by the tunnel shooting blast machine, e.g., AC 380V 50Hz. In a machine that has more energy-efficient technology, the required energy level may be less for the same job in other machines.
Dimensions:
Width, tunnel length, and height, i.e., the three size-relevant specifications indicate the minimum size of parts this machine can blast.
Dust Control:
How this is managed. Is there an integral dust extraction and treatment system? What about filters and their cleaning? Dust control reduces contamination and results in clean exhaust air. Other ways to manage tunnel dust include being connected to a central dust system or bagging the dust to treat it entire?
Logistics:
What is the most efficient way to load and unload parts into and out of the machine? Are conveyor systems used, or can the tunnels develop into a more extensive system by connecting with other tunnels, merging, or dividing? Is there an integration with supply chains, including automated warehouses and handling systems?
Cleaning and upkeep are crucial for the tunnel shot blast machine to function uniformly, reliably, and effectively over a long period. It would help if the essential blast is done weekly, wiped out monthly, and occasionally checked and replaced.
Daily:
Before starting after the previous day's stopping, do the following:
Check the electric power cable and air pipe for tunnel injuries or wear, including slip ring brushes and bearings.
Inspect all doors to ensure they are secure and the locking mechanisms are working correctly. Throughout the machine's length, check that there is no blast media build-up on its sidewalls, floor, or roof.
Ensure the dust extraction system is operating correctly.
Weekly:
After opening all access doors, conduct a more thorough inspection by looking through the entire tunnel length to identify any damage that may have occurred through a blast.
Look at critical parts in the recycling system, such as screens, hoppers, classifiers, etc., to see if the blast media has caused its usual wear and tear so that spares can be ordered in time.
Take the last media build-up and clean the sidewalls and floor, mainly the air empirical classifier.
More thorough dust clearing should also be done. Bag filters need to be shaken out, and hoppers emptied.
The uses of tunnel shot peening machines are plenty and varied. They are mainly used in heavy industries during pre-surface treatment of different kinds of metal substrata. The metals get impacted by small steel shot pellets in this machine that are propelled by high-powered rotating turbines. The surface of the metal gets cleaned by this process, removing any rust, scales, or dirt deposits, through one of the many blasting techniques.
These machines are widely used in the construction and manufacturing industries for ferrous and non-ferrous alloys, such as titanium, copper, magnesium, aluminum, brass, steel, etc.
Some of the common areas these machines can be found in are:
When selecting a tunnel shot blast machine for specific uses, it is important to assess key features and specifications that are in line with particular application needs. Focus on the primary components of the machine that make it suitable for a particular job requirement.
A great place to begin the selection process is by defining the specific application needs. Make sure to consider the type of work piece material, geometry, and the kind of surface requirement. The focus should be on determining the desired surface finish, whether clean, roughened, or oxide-removed, and the quality sought.
After defining the application needs and priorities, it is essential to explore blast media options. Ultimately, selecting the right one depends on its compatibility with specific workpiece materials and the surface finish goal. Ensure that the tunnel machine utilizes blast media that is effective for the metal being worked on.
Consider the machine's cleaning capacity, which is determined by its throughput and cycle time. Ensure that the tunnel blast machine chosen can handle the required processing volume to meet production demands without causing bottlenecks in the workflow. In addition, the power of the machine's blasting system is an important factor to consider. The machine should have sufficient blasting power to achieve the desired surface condition without damaging the workpiece.
Focusing on the tunnel machine's design and construction is important, as this will determine the level of maintenance required. Consider the accessibility of components such as blast wheels, separators, and dust collection systems for cleaning and maintenance tasks. Choosing a machine with low maintenance requirements and robust construction can minimize downtime and reduce long-term operating costs.
Finally, it is important to consider the machine's environmental impact and filtration system. Buying a tunnel shot blast machine with efficient dust collection and separation systems helps to maintain a clean and healthy workplace. It also minimizes the release of airborne particulate matter to the environment.
Q1: What is the difference between a tilt and an off-center shot in a tunnel shot blast machine?
A1: In a tunnel shot blast machine, the type of nozzle arrangement used for the machine can vary with different applications. One of the common arrangements is the use of nozzle tilting. In this case, the nozzles are tilted toward the product being blasted. Another common arrangement is off-center blasting, where the nozzle is centered and directed off to the sides toward the product.
Q2: What are the two common types of air recycling systems in tunnel blast machines?
A2: The two common types of air recycling systems are pneumatic separation and cyclone separation. In a tunnel machine using cyclone separation, the dust-laden air is directed into a cyclone separator where the dust particles fall into the hopper, while clean air returns into the facility.
Q3: What are the benefits of using a tunnel shot blast machine on workpieces?
A3: The machine is able to efficiently and uniformly blast a workpiece's entire surface. It has the capacity to process large quantities of workpieces at a high rate. Durable construction permits the machine to be used for heavy-duty applications. Finally, shot recycler systems allow control of the entire process to afford economic, environmental, and plant safety benefits.
Q4: What is the difference between induction and drum motors in a tunnel shot blast machine?
A4: An induction motor uses alternating current to produce a magnetic field that causes the motor shaft to rotate. On the other hand, a drum motor has the entire drive unit internally housed within a drum. A drum motor in a tunnel shot blast machine may be used to directly drive a roller, while an induction motor may be used to drive a coupling or gearbox that drives a roller.
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