Rösler Oberflächentechnik GmbH

Vorstadt 1, 96190 Untermerzbach
Germany
Telephone +49 9533 924-0
Fax +49 9533 924-300
info@rosler.com

Location

Hall map

GIFA 2015 hall map (Hall 16): stand G40

Fairground map

GIFA 2015 fairground map: Hall 16

Contact

Müller Barbara

Abteilungs-/Gruppenleiter
Marketing, Vertrieb, Werbung, PR

Vorstadt 1
96190 Untermerzbach, Germany

Phone
09533 924 802

Fax
09533 924 300

Email
b.mueller@rosler.com

Our range of products

Product categories

  • 10  Casting machines and pouring equipment
  • 10.03  Peripheral equipment and auxiliary materials for die casting (die casting dies see 17.03.01)
  • 10.03.07  Trimming machines for die casting
  • 11  Knock-out, fettling and finishing
  • 11.01  Knock-out
  • 11.01.04  Decoring equipment

Decoring equipment

  • 11  Knock-out, fettling and finishing
  • 11.02  Blasting plant and accessories
  • 11.02.01  Pneumatic blast cleaning machines

Pneumatic blast cleaning machines

  • 11  Knock-out, fettling and finishing
  • 11.02  Blasting plant and accessories
  • 11.02.02  Airless shot-blasting machines
  • 11  Knock-out, fettling and finishing
  • 11.02  Blasting plant and accessories
  • 11.02.03  Pressure water blasting plants

Pressure water blasting plants

  • 11  Knock-out, fettling and finishing
  • 11.04  Fettling installations
  • 11.04.01  Deflashing machines
  • 11  Knock-out, fettling and finishing
  • 11.05  Grinding machines and accessories
  • 11.05.06  Grinding technology, others

Grinding technology, others

  • 12  Surface treatment
  • 12.06  Surface treatment plants

Surface treatment plants

  • 22  Environmental protection and waste removal
  • 22.02  Waste water cleaning plants

Waste water cleaning plants

  • 22  Environmental protection and waste removal
  • 22.10  Water treatment plants

Our products

Product category: Trimming machines for die casting

New manufacturing line with integrated continuous surface fi

Gentle deburring of complex die-castings

Rösler has developed a continuous feed vibratory finishing system 780/2E-LR-So for a new diecasting line and has been completely integrated into the manufacturing flow. The component / work pieces are automatically fed into the system on a 20-second time cycle.

The Julius Schüle Druckguss GmbH, founded in 1951, specialises in the manufacturing of precision aluminum die-castings for automotive, pneumatic and gas heating assemblies. New additions to the company’s product range required the installation of a new casting line at its headquarters in Schwäbisch Gmünd. The new line produces engine cradles with an integrated steel axle. This posed considerable technical challenges to the casting process itself as well as to the subsequent manufacturing steps. For this reason, the Rösler vibratory finishing system was custom engineered for this particular application. Herbert Nowak, production manager at Schuele Druckguss, explains: “On the one hand, we require a very gentle single component processing with the requirement for breaking of sharp edges and smoothing of uneven component surfaces. On the other hand, short processing times allowing a high throughput in a fully automatic 3-shift operation is a must”.

Surface finishing system and processing media perfectly adapted to each other

Rösler met this challenge with the innovative machine concept of the Long Radius

R 780/2E-LR-So, that could be perfectly integrated into the new casting line at Schuele.

Herbert Nowak explains the company’s decision for choosing the Rösler finishing system:

“Because of the comprehensive technical knowledge of the Rösler sales staff and our excellent experience with other equipment, Rösler is one of our preferred suppliers”.

With a processing channel of 350 mm (14”) wide and 6,000 mm (236”) long this Long Radius system offers an intensive finishing process in a highly compact machine design concept and with a surprisingly small footprint. The consumables (grinding media and compound) required for the finishing process at Schuele were determined through processing trials in the Rὅsler test lab.

Work piece loading in 20-second cycles

The raw components produced by the casting cell are transported by conveyor belt to the trim press. A robot equipped with an image recognition system picks up the castings and places them into the press in the correct position. After trimming, the robot picks up the components and transfers them into the vibratory finishing machine in precise 20-second cycles. The rounded shape of the work channel / profile ensures the quick embedding of the components into the grinding media and optimises the media/work piece movement. This explains the excellent finishing results achieved in a surprisingly low total process time up to a maximum 10 minutes.

The separation of the finished components from the media is as gentle as the loading and processing: A specially designed separation screen guides the finished work, allowing a very gentle discharge from the LR machine. Subsequently, the cup shaped aluminum die-castings are transferred to a camera-controlled “flipping” station placing them to an optimum position for the following inline washing/cleaning process.

Effluent treatment included

Schüle Druckguss is recycling the process water from the vibratory finishing system. The water is cleaned in a compact semi-automatic centrifuge model Z 800 HA. With a centrifugal force of up to 2,000 g this system effectively separates the solid particles from the liquid. Even very tiny and light solids and particulate are deposited on the inner wall of the sludge basket inserted into the rotary drum. The sludge can be easily removed from the sludge basket.

Pleased with the results so far, Herbert Nowak summarises: ”The new vibratory finishing system not only enables the optimum processing result in the given cycle time, but provides by design, a very gentle handling of the components”.

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Product category: Airless shot-blasting machines

Rösler Gamma® 400 G

New, highly versatile blast turbine helps reduce costs for surface treatment

Rösler Gamma® 400 G – provides improved blast performance, higher uptimes and easier maintenance

Shot blasting for surface cleaning and surface preparation represents an indispensable manufacturing phase in many metal-processing industries. Generally, blast turbines are the most expensive component of many shot blasting system, requiring significant upkeep in terms of maintenance and wear parts.

At the GIFA exhibition in Duesseldorf, Rösler will present its newly developed and extremely versatile Gamma® 400 G blast turbine which will be setting new standards in cost efficiency. For example, compared to conventional turbines the Gamma® 400 G offers a 100% higher uptime and a significantly improved blast performance together with drastically reduced maintenance costs.

Distinctive features of the Gamma® 400 G are the Y-shaped throwing blades, providing many technical advantages for this innovative turbine, for which a patent application is pending. By simply turning the blades around, both sides of the throwing blades can be utilised. This design helps double the uptime and results in drastically lower wear part costs.

Quick and simple exchange of the throwing blades

With conventional twin disk blast turbines the replacement of worn throwing blades is complicated and time consuming: The impeller and control cage must be completely disassembled before the old blades can be loosened, removed and new blades inserted through the center of the twin disks. With the new Gamma® turbine design the worn throwing blades can be easily loosened, taken out from the side and replaced with new blades after simply removing a maintenance side cover. This quick blade exchange with easy access to all wear components makes turbine maintenance not only simple but also saves a significant amount maintenance time, further helping to increase that all important uptime and reduction in operating costs.

Blast performance improvement by 15 – 20 percent

Another key feature of this unique blade design is the improved turbine efficiency. Compared to straight blades the curved throwing blades of the Gamma® 400 G allow a much more fluid flow of the blast media. Without increasing the turbine diameter this improves the media acceleration and produces significantly higher throwing speeds. The end result: A 15 – 20 percent higher blast performance with, subsequently, shorter processing times for many shot blasting applications!

Flexible turbine drive power and media throughput

The new Rösler blast turbines have a diameter of 400 mm (about 16”). They can be equipped with drive motors from 11 up to 30 kW and generate media throughputs of up to 400 kg/min (880 lbs./min). With this wide range of power options the Gamma® 400 G is suitable for practically any shot blasting application. The Y-blades are produced by a special manufacturing process that also allows fabricating the turbine components in a highly wear resistant tool steel.

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Product category: Airless shot-blasting machines

Special foundry version of spinner hanger shot blast machine

Coping with the challenging task of core sand removal

For the removal of sand cores from various grey iron pump components the Bobruisk Machine Building Plant purchased a spinner hanger shot blast machine, type RHBE 27/32-F, from Rösler. The customer specifications called for a special design that can cope with the harsh foundry conditions and offers reduced equipment wear and high uptimes for a highly cost efficient shot blast operation.

The removal of sand cores from steel castings poses special challenges to many shot blast machines. Abrasive core sand increases wear of components such as the blast chamber and blast turbines resulting in higher operating costs and lower uptimes.

Therefore, it is not surprising that wear rate and uptime were key factors, when the customer decided to purchase a new shot blast machine as part of a foundry modernization project. Bobruisk Machine Building, located in Belarus, is the largest manufacturer of special pumps for oil refineries, the petrochemical industries, the steel and mining industries and many other sectors in the former GUS countries. The pump components consist of grey iron and steel castings and require an intensive internal and external blast cleaning step after having been cast.

Convincing adaptation to the harsh foundry operating conditions

For the required shot blast machine Bobruisk had issued a tender invitation to which eight equipment suppliers responded. In the end the customer decided to purchase the spinner hanger shot blast machine RHBE 27/32-F from Rösler. A key factor was the cost efficiency of this shot blast system designed as special foundry version with optimized wear protection of critical equipment components. This included the fabrication of the blast chamber from 10 mm (0.4”) manganese steel with additional manganese steel wear liners on the blast chamber sidewalls. The blast zone itself is protected against wear with 25 mm (1”) thick hard metal plates. The wear liners require no special fastening elements allowing easy and quick installation. In addition, all liners overlap leaving no gaps so that the blast chamber is optimally protected against wear.

The foundry version of this shot blast machine can be equipped with different blast turbines. The Bobruisk spinner hanger machine is equipped with four turbines, type hurricane H 42, each with an installed power of 22 kW. The same shot blaster can also be equipped with Rösler Long Life high performance turbines of the Gamma series. These are made from hard metal and offer up to 16 times longer lifetime. The pump components are either processed as large, single pieces or in batches of multiple, smaller pieces with batch weights of maximum 5 metric tons. Adjustable shell valves allow adjustment of the media flow taking into account the component size and shape. A special blast program for core and moulding sand removal allows sequential activation of the turbines. This allows the sand to be removed in smaller quantities and thus prevents a sudden surge of sand that could overwhelm the blast media cleaning/classification system.

Blast media classification with a cleaning efficiency of up to 99.7%

Another technical highlight of the RHBE 27/32-F is the blast media cleaning system designed for sand contents in the media of up to 20%. Coarse particles are removed from the media/sand mix with a vibratory screening system before it is guided to a dual drum magnetic separation system. A clever guide system ensures that the media/sand mix is evenly distributed over the complete drum width thus producing a very thin media/sand curtain. The strong electro magnets placed inside of the drums guarantee a separation efficiency of up to 99.7%. The low residual sand content in the blast media helps to significantly reduce the overall wear rate.

The dust collector is equipped with filter cartridges that are specially designed for a relatively heavy sand load and offer a longer uptime. The residual dust is < 1 mg per m3 of cleaned air.

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Product category: Deflashing machines

Outstanding surface finish of drive components

“Revving up” with high tech shot blast solutions

Tailor-made automatic shot blast systems allow the targeted high quality surface treatment of powertrain components such as engine blocks, crankshafts and cylinder heads.

Weight and size reduction of key components – this is a catch phrase that describes important trends in the automotive industry. But such ambitious targets can only be met by – among other things – excellent surface finishes of the various drive components. At the same time, improved manufacturing efficiencies are demanded. That is why leading car & truck manufacturers and their suppliers are utilising custom engineered, integrated shot blast systems for blast cleaning and peening of engine blocks and cylinder heads supplied by Rösler.

Adaptation to the customer’s requirements – down to the last detail!

A world-class automotive supplier is using a Rösler RWK swing chamber machine for blast cleaning and deburring of aluminum cylinder heads and engine blocks. This system has two chambers, which allow the loading and unloading of work pieces parallel to the shot blast process. A special transport belt carries the raw engine blocks to a pre-defined position to the blast system. There, a robot picks up one work piece at a time and places it in the blast chamber. After the shot blast process, the same robot removes the work piece from the blast chamber. Using a precisely defined manipulative movement by the robot any residual blast media is discharged from the internal passages of the engine block before being placed on the transport belt in the exact position required for the next manufacturing step.

The same customer is using a Rösler shot blast machine, type RDV, for the precision blast cleaning of complex work piece; areas, such as undercuts. This blast system, equipped with two Rösler Long Life high performance Gamma 330 turbines with 11 kW
drive power each, is designed for the simultaneous blast cleaning of two engine blocks at a time, and rotating during the blast process. Loading and unloading of the work pieces

is also handled by robots.

A Chinese customer is blast cleaning cast aluminum engine blocks with four into the manufacturing process integrated shot blast systems that are based on the Roboblaster concept, a combination of shot blast machine and 6-axis robot that can be used for various shot blasting tasks for example deburring, desanding of castings up to more sophisticated shot peening applications. These systems are equipped with Hurricane® turbines with 15 kW drive power. There is one robot per each shot blast system, automatically removing residual blast media after completion of the blast process with achievable cycle times of less than 30 seconds.

At a German car manufacturer the technical specifications called for partial blast cleaning and deburring of cylinder heads with, at the same time, masking (protection) of drilled holes and a matrix code. For this application Rösler utilised two compact RWK 6/12-2 swing chamber shot blast systems the dimensions of which had to be adjusted to the available space available at the customers location. The loading and unloading of the work pieces are handled by a robot, for which Rösler had to develop a special gripper system. This allows the gripping the cylinder heads of differing design. The surface area that must be blasted is always on the upper side / position. The drilled holes and the matrix code are automatically protected by pins, and respectively, a protection plate.

Besides designing, manufacturing and supplying shot blast systems for engine blocks and cylinder heads, Rösler has supplied numerous custom engineered systems for the blast cleaning of work after heat treatment, descaling of crank shafts and shot peening of gear components to OEM’s and suppliers all over the world.

 

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Product category: Surface treatment plants

Surf-Finishing

A new mass finishing technology for automated finishing processes, reduces cycle times

Targeted “surfing” in a bed of finishing media

Fully automatic processing, extremely short cycle times, high process stability, repeatability and finishing of precisely targeted surface areas – these are the many benefits of the new Rösler “Surf” Finishing technology for deburring, surface grinding, smoothing and polishing of delicate, high-value work pieces with complex geometries.

Growing demands for improving the quality of finished surfaces, for stability & repeatability of the finishing processes together with the need for further increased cost efficiencies, requires innovative technologies for treating high value components with more complex geometries. Röslers Research & Development has met this challenge head-on with the newly created “Surf Finishing” technology. It allows fully automatic dry or wet processing of delicate work pieces to be accommodated, which, to date, could only be finished with highly unreliable and costly manual methods or with very expensive mechanical systems.

The ideal combination of robotic handling and special media motion

Depending on the finishing application, the Surf Finishing technology uses either one or multiple 6-axis robotic arms to lower the work pieces into a rotating processing bowl filled with grinding or polishing media. This process allows either all-around surface finishing of the work pieces or the selective treatment of targeted surface areas. The simultaneous “surfing” of the work pieces through the grinding media and the rotation of the processing bowl generate an extremely high grinding pressure. The result is a very intensive process and a perfect surface finish, in amazingly short cycle times.

Easy integration into manufacturing lines

Surf Finishing guarantees very high process stability and repeatability and is, therefore, the ideal technology for single component treatment in the aerospace, automotive, hydraulic, energy generating and many other industries where precise deburring, surface grinding, smoothing and polishing are essential. Multiple component / part specific processing programs are stored in the system controls from where they can be quickly retrieved by the operator.

The treatment process can be augmented by material handling and other auxiliary equipment such as component / part transport systems and part washers. Therefore, the Surf Finishing equipment can be easily integrated into complex, automated manufacturing lines.

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Product category: Water treatment plants

Rösler centrifuges....for the efficient cleaning of industri

Keep clean!

Coolants, the sludge from paint booths, the process water from industrial surface cleaning operations, or the process water from the treatment of glass and ceramic materials – whenever it comes to the cleaning/recycling of industrial liquids, the proven centrifugal filtering technology from Rösler offers numerous economic and technical benefits. Centrifugal filters – with manual or fully automatic sludge discharge -- remove solid materials from the process liquids down to very small particles through a purely physical/mechanical process. This technology eliminates the need for filters or chemical compounds which are costly to buy as well as being expensive to dispose of as waste material. Moreover, because the residual water content in the sludge generated by centrifuges is as low as 30%, sludge disposal costs can be significantly reduced.

Semi-automatic centrifuges for 2- and 3-phase separation

With a rotary drum speed of up to 3,000 RPM the semi-automatic centrifuges, built for easy „plug-and-play“ installation, offer an excellent separation performance. They are generating such a high centrifugal force that even very small and light particles are safely removed from the liquid. The sludge is collected in a polymer basket that can hold 22 kg (48 lbs) and is inserted into the rotary drum. For removal of the sludge this “basket” is simply taken out of the drum. Systems with a smaller capacity are currently under development.

Besides the separation of solids from the liquid phase the 3-phase centrifuges also allow the separation of liquids with different densities, for example the removal of unwanted oil from coolants. The process liquid contaminated with oil and solid particles is fed into the centrifuge at a constant flow rate. Because of the different densities of the three “phases” (solid/liquid1/liquid2) the solids and the two liquids are separated from each other. For removal from the rotary drum the two separated liquids are caught by two dedicated collecting tubes which transport them to their respective destinations.

Automatic sludge discharge for round-the-clock operation

Depending on the specified cleanliness requirements and the particle size and weight limits, the automatic centrifugal systems Z 1000 from Rösler offer a capacity of up to 100 liters/min (25 gal/min). They are the ideal solution for applications with very large process liquid volumes. The extremely high acceleration in the rotary drum of up to 2,000 g easily separates solid particles with a size of 2 µ or larger from the liquid. For larger volumes Z 1000 systems automatically discharge sludge from the rotary drum. The innovative discharge technology developed by Rösler offers significant technical advantages: While in conventional automatic centrifuges the peeling knife, powered by a geared motor, is continuously rotating with the rotary drum, the peeling knife in the Z 1000 centrifuges is stationary. At the beginning of the peeling cycle the knife is pushed pneumatically towards the wall of the slowly rotating drum and peels out the sludge without any load on the drum bearings. The peeling knife itself is made from highly wear resistant steel. Upon completion of the peeling cycle the inside of the drum is rinsed to flush out any residual sludge.

Solidly built and easy to maintain

The Rösler centrifuges distinguish themselves through their high performance and their rugged and maintenance-friendly design. For example, a key feature of the Rösler centrifuges is the indirect drive of the rotary drum by V-belt allowing the installation of heavy-duty drum bearings. For the cleaning of corrosive liquids throughout a wide pH range or process liquids with a high salt content, for example after TEM or ECM deburring applications, Rösler offers all centrifuges in a stainless steel version made from either 316 or 320 material.

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About us

Company details

Rösler Oberflächentechnik GmbH is international market leader in the production of surface finishing, shot blasting machines, painting systems and preservation lines as well as process technology for the rational surface finishing (deburring, descaling, sand removal, polishing, grinding…) of metals and other components. Besides the German plants in Untermerzbach/Memmelsdorf and Bad Staffelstein/Hausen, the Rösler Group has fifteen branches in Great Britain, France, the Netherlands, Belgium, Italy, Spain, Austria, Switzerland, Romania, Russia, China, India, South Africa, Brazil and the USA.

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Company data

Sales volume

200-499 Mio US $

Number of employees

1000-4999

Foundation

1933