Application: Abrasive blast cleaning of stainless steel components for cosmetic reasons and to eliminate the need for additional finishing.
Application: Abrasive blast cleaning of gun components to prepare surface for coating application.
Market: Power Generation
Application: Refurbishing steam turbine diaphragms using abrasive blast cleaning
Market: Oil & Gas
Application: Abrasive blast cleaning of fracking valves prior to coating Read more
Market:Oil & Gas
Application:Shot peening of off-shore drilling pipe to improve compressive strength and reduce fatigue failures. Read more
We are excited to announce dates for the 42nd Spring Training Seminar at Empire Abrasive Equipment in Langhorne, PA. This spring, the seminar will be held between Tuesday April 29th and Thursday May 01st. This much-awaited biannual event is very popular among Empire distributors and select customers, attracting a global audience.
Empire has designed this seminar to suit the requirements of a wide spectrum of industry members. An entrant into the field of blast cleaning and shot peening is assured to leave the sessions with a good understanding of not only the Empire product range, but also cognizance of blast techniques. Participants with prior knowledge of the industry and product will gain a richer perspective of applications and equipment by sharing their knowledge and learning from peers in the industry.
This seminar has traditionally attracted active technical discussions between participants and Empire experts on common issues faced by users of blast cleaning and shot peening equipment. The level of expertise available in a single location to respond to such questions is unmatched anywhere else in the industry. More importantly, we have designed this seminar to be hands-on with our demo lab and shop available for ready references.
Some of the topics that our experts will cover include:
• Principles of blasting (suction and pressure)
• Standard and modified cabinets
• Media reclamation and dust collection
• Portable equipment
• Automation and Robotics
• Shot Peening principles
• Airblast rooms
• Safety equipment
• Start-up tips
• Customer service
Please contact your Regional Sales Manager for a detailed seminar schedule.
What’s new this session?
Empire has evolved as an airblast equipment manufacturer over the years. A vast majority of the automated equipment manufactured incorporates robotics. Most recently, Empire was awarded a several contracts to build sophisticated robotic systems. We expect one of these systems to be in its final stages of assembly during the course of this seminar. We will also be demonstrating our newly acquired robotic software and its capabilities to animate path programs – a tool that will greatly enhance your presentation when discussing such equipment with your customers.
Indexing Turntables are among the most common equipment to automate your blast operation. Their design has certain inherent features that promote versatility, ease and economy of operation. Such machines are often classified by their main table size, quantity of nozzles, and type of media propulsion, i.e. suction and pressure.
Empire TT Indexing Turntable Machines are manufactured in three standard versions, TT-20 (20″ diameter), TT-36 (30″ diameter) and TT-48 (48″ diameter). Our focus for discussion here is the smallest of the range, TT-20.
The TT-20 was designed with the goal of providing a cleaning or peening solution with all the versatility of an indexing turntable machine, all in a very compact footprint. The TT-20 is available to you with either four suction or pressure nozzles, as required by your application. The tenacity of your cleaning application, or the intensity requirements of your shot peening application will determine the choice of media propulsion.
As with all indexing turntables, in the TT-20 loading/unloading of parts takes place under the cover of blasting.
The engineers at Empire place special emphasis on your individual requirements, whether it be space constraint in your plant or a special technique in your manufacturing process requiring the inclusion of additional process control components in the TT-20. In the current example (see insert), the TT-20 performs a critical peening operation on aerospace components requiring a vibratory classifier, multiple outlet pressure vessel and dust collector, all in a very compact footprint in order to fit customer’s existing plant layout and constraints.
Industry and Applications:
- Medical : A relatively recent adopter of blast cleaning and shot peening processes leaves our customers in the medical industry with very limited space availability. With a minor table modification to the TT-20, it can be upgraded to a 12 station configuration, producing two cleaned or peened medical component with every index of the main table.
- Aerospace: When processing of small blades with vent / cooling holes, the TT20 provides a pressurized part rotation station that blows air up through the blade to and prevents media from staying lodged in critical internal areas. In the absence of such an arrangement, the blast media has a tendency to clog the holes resulting in a scrap part.
- Automotive: Small transmission components
- Friction parts
- Cylinders for airbags
- Brake rotors
o Work handling (main table & satellites)
o Media Storage hopper
o Media reclaim
o Make Up hopper
o Dust Collector
o Three (3) blast stations provide excellent coverage
o 4 to 8 suction blast nozzles
o 2 to 6 Pressure blast nozzles
o 6 or 12 station satellites
o 1 or 2 part index (depends on part sizes)
o Tight footprint ideally suited to work in a cell
o Systems PLC permits versatility of operation
o Vertical sliding work doors seal the blast operation for dust and noise
o Faster cycles due to smaller turntable (Quicker index time)
o Ease of accessibility for maintenance
o Urethane ducting (optional item) helps reduce foot print
The blast system is regularly replenished using an automatic Make-up Hopper. This hopper adds virgin media to the system whenever the storage hopper runs low on media. This controlled replenishment helps maintain proper operating mix resulting in a consistent part finish.
The TT20 offers many safety features including:
o Light curtains at load/unload station
o Door safety interlocks
o Door locks (if needed)
o Vertical sliding doors
As with all automated Empire systems, the TT-20 is completely tested with abrasive, with customers in attendance with their production parts, prior to shipment. This ensures trouble-free installation and quick start-up at the installation site.
Contact Empire to learn how the TT-20 or one of our suitable systems for your application can add to the profitability of your operation If unsure, why not visit our demo facility in Langhorne, PA to process your components in one of our several demo machines?
Welcome to the most sophisticated and comprehensive test facility for airblast peening and cleaning applications. Welcome to the Demo Center at Empire in Langhorne, PA (USA).
Whether you are an existing user of cleaning or peening equipment, or a novice to the process, the Empire Demo Center has tremendous potential with tips to increase your productivity and add to the profitability of your operation.
As an advanced manufacturing plant, you have other critical parts of your production process that demand your attention. Most often, this results in an unintentional neglect of processes such as blast cleaning and shot peening. Interestingly, this neglect could lead to higher operating costs and equipment wear than normal. Let’s take the instance when your customer has introduced a new product and would like to partner with you and develop the cleaning or shot peening specifications and procedure for this new component. Empire is here to help with its demo center in both instances. Here’s how:
- Review your existing application and equipment use with Empire by testing your production parts in one of over ten machine types on Demo Center.
- Demo results could prove that maybe you have been using higher blast pressure than required, perhaps a different media type or size could provide you better results. Both changes will reduce your operating costs.
- The Demo Center has equipment with varying and increasing degrees of automation. If your new production needs demand a slightly higher degree of automation, the Demo Center provides you the choice of equipment to test the same.
- Shot peening is a process that’s either misunderstood or completely new to a lot of end users. Visit the Demo Center. Our experts in this process will carry out peening tests on your part samples, to varying levels of impact energy (shot peening intensity), that you will be able to conduct fatigue tests on at your plant. Along the way, we will also help you develop your peening parameters and even help you conform to an established specification.
The Empire Demo Center has the entire range of airblast equipment available for tests, starting from the simplest manual handblast cabinet to sophisticated robotic cells for single part flow. All this equipment is available for your testing, most times without any charge.
We look forward to seeing you in our Demo Center and help you increase the profitability of your cleaning and peening operation!
For some applications, a part’s finishing specifications may be beyond the capabilities of a standard blasting cabinet. Empire is able to take the standard product line and modify the cabinets and technology to fit the application requirements. As an example, a customer may have a part that weighs 2,000lbs.; however the standard Pro Finish cabinet can only handle a 1,000lb capacity. Through Empire’s modified program, the upgraded design could include a raising the gloves and window in the cabinet to accommodate the customer’s largest part an in/out turntable or modified DC drive for part handling.
Typically the process would begin with an RFP through an authorized Empire distributor. The proposal information is filled out by the customer and aided by the distributor to get an understanding of how they want to process the part and cabinet features such as a turntable, outside platform etc. We develop a quotation that would fit a certain range of adjustments to standard equipment. During quoting proposal drawings are sometimes developed for customer clarification.
This proposal is sent to the customer for review and feedback. We will put together an approval drawing after the order is accepted. The process usually goes smoothly since I believe we are modifying the top cabinets in the industry and most companies are familiar them.
During the proposal stage we may get a sample part to review and possibly process. Processing would be performed by Empire’s Product Support Team in our demonstration lab. After the proposal stage is complete and an order is received an approval drawing is generated with all of the important details of the system shown.
After the approval drawing is finalized the order is released to Production and Fabrication. From there the modified cabinet goes to paint then on to final assembly. After assembly is complete we perform pneumatic and electrical tests to ensure the system is working properly.
Final inspection is performed by:
- Assembly department
- Technical service department
- Designer of the project
- Product manager of the Modified Cabinets division
With stringent inspection and quality checks the cabinet is ready for shipping and installation.
At this point the customer may come to Empire’s facility to inspect the system, or for a “runoff” to test the system. If the test is satisfactory, the cabinet is cleaned and prepared for shipment. The distributor then helps to setup the system upon arrival at the customer’s facility. Regional managers may also attend the setup and help with training if necessary.
A modified cabinet project will generally take approximately 8 to12 weeks from inquiry to installation.
Empire offers two distinct approaches to achieve the best finishing solution for each robotic application. The first approach is a pre-engineered blasting system. These systems have two types of design layouts starting with two forms of pedestal-mounted robot machines and an inverted robot machine. Most applications fit these machines with the ability to process parts up to 2ft dia. x 2ft high. In each solution the robot is manipulating the blast nozzle. Each design includes a dc motor-driven 7th axis that can be upgraded to a servo-driven axis which provides the operator with infinite flexibly and more precision.
A main advantage of the pre-engineered system is that engineering costs are removed since it is predesigned. At the same time, a number of standard options are available that will cost less than custom-designed systems. Lastly, a pre-engineered system can be produced much faster that a custom-built solution.
A custom-built system is used generally if a part is too large for a pre-engineered solution or if it is more desirable to manipulate the part instead of the nozzle. The customer may have a specific material handling need that is out of the range of the pre-engineered system capabilities.
To determine which approach is the best solution, Empire analyzes customer-supplied drawings and part dimensions, integration and support needs. The plant layout is reviewed and becomes part of the design criteria to ensure proper installation and efficient production. Empire arranges a meeting with the customer if necessary then provides a proposal.
Once the equipment is produced, a factory acceptance test is conducted at Empire’s facility. The customer visits Empire to test the equipment and receive operational and maintenance training. Once the test is complete and the equipment is approved, Empire’s service technicians can be provided to supervise the installation and startup as well as provide on-site training.