Industry: Coating Suppliers and Manufacturers
Objective: To automate the air blast etching of large flat sheets, reducing operator involvement and improving productivity, while ensuring a uniform blasted surface.
Background
A leading coating supplier and manufacturer approached Empire with a challenge: they needed a reliable, automated system that could air blast etch large flat sheets of various sizes with minimal operator involvement. The system had to achieve consistent, uniform coverage on one side of the sheet, while also being housed in a self-contained environment to protect the operator and maintain safety standards.
Challenges
- Uniform Surface Finish: The client needed to ensure uniform surface blasting across large flat sheets, regardless of size.
- Operator Safety: Operator safety was a concern due to the hazardous environment of the blasting process.
- Reduced Operator Involvement: Automation was key to lowering labor costs and minimizing human error, while allowing the operator to focus on high-value tasks.
- Flexibility for Various Sheet Sizes: The system needed to process sheets of varying sizes in succession without extensive manual intervention or system recalibration.
Solution: Automated Oscillating Nozzle Blast System
Empire developed a fully automated air blast etching system with oscillating pressure nozzles and PLC-controlled automatic system controls. This innovative system processes large sheets in a precise and repeatable manner with minimal operator involvement.
Key Features:
- Oscillating Nozzle System: The blast nozzles oscillate vertically across the surface of the sheet, delivering a uniform blast. As the sheet indexes through the blast enclosure, the nozzles cover every inch, ensuring even coverage without any missed areas or over-blasted sections. The nozzles move up and down the length of the sheet as it advances, providing consistent surface treatment.
- Precision Indexing: The sheet is indexed forward in controlled increments (as small as 1 inch), ensuring precise movement and complete coverage. This indexed movement allows the blasting process to be stopped and restarted without losing the uniform finish, providing the flexibility needed in case of process interruptions.
- Automated PLC Control: The PLC (Programmable Logic Controller) system allows for hands-off operation, reducing operator involvement while maintaining total control over the process. Operators can easily adjust settings, monitor progress, and stop or restart the process without compromising the quality of the finish.
- Media Makeup Hopper: To further minimize operator duties, the system includes a media makeup hopper. This feature automatically replenishes the blasting media, eliminating the need for manual media refills during operation.
- Powered Conveyor and Load Stations: The automated conveyor system enables easy handling of sheets, allowing them to be loaded on one side and unloaded on the other without heavy manual lifting or time-consuming adjustments. This feature boosts productivity by allowing continuous operation, where sheets can be processed one after the other.
Results
- Uniform Finish: The automated system consistently delivers a high-quality, uniform blasted surface across all sheet sizes. The oscillating nozzles ensure even coverage, eliminating operator inconsistencies.
- Increased Productivity: With minimal operator involvement and the powered conveyor system, sheet loading and unloading became significantly faster. This allowed for continuous processing of multiple sheets, improving throughput.
- Enhanced Operator Safety: By reducing operator interaction with the blasting process, the system increased workplace safety. Operators remained out of harm’s way, with the PLC controls allowing them to oversee the process remotely.
- Reduced Labor Costs: Automation not only minimized the need for operator involvement but also reduced the risk of human error, leading to fewer reworks and lower overall operational costs.
Conclusion
Empire’s automated air blast etching system provided the client with a cost-effective and efficient solution to their blasting needs. The system’s automation capabilities, combined with its precision and safety features, resulted in improved productivity, consistent surface finishes, and enhanced operator safety. Through this customized solution, the client was able to reduce manual labor, streamline operations, and ensure high-quality etching for their large flat sheets, making it a success story for both the client and Empire.