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Herzensangelegenheit Mitarbeiter-Ehrung – Rösler feiert endlich wieder im großen Rahmen

Im Jahr 1982 wurde Helmut Kohl Bundeskanzler der Bundesrepublik Deutschland, in Erlangen wurde das erste Retortenbaby des Landes geboren, und das US-Nachrichtenmagazin „Time“ wählte den Computer zur „Maschine des Jahres“. Alles entscheidende Ereignisse, die den Lauf der Welt maßgeblich beeinflusst haben. Für Maria Zillig und Thomas Eberth war das Jahr 1982 aber noch aus einem anderen Grund besonders einschneidend: Es war das Jahr, in dem sie ihre Ausbildung zur Industriekauffrau und zum Industriekaufmann begonnen haben. Und zwar bei der Rösler Oberflächentechnik GmbH in Memmelsdorf / Untermerzbach beziehungsweise Hausen. Dort arbeiten sie auch heute noch. Ganze 40 Jahre später. Genauso wie ihr Kollege Detlef Griebel, der ebenfalls seit 1982 bei „seinem“ Rösler beschäftigt ist. Einem Unternehmen so lange die Treue zu halten ist alles andere als selbstverständlich. Deshalb hat die Rösler Oberflächentechnik GmbH diese, und 39 weitere langjährige Mitarbeiter, jetzt im feierlichen Rahmen für ihre lange Unternehmenszugehörigkeit geehrt. Für den Geschäftsführenden Gesellschafter Stephan Rösler ist die jährliche Ehrungsfeier eine echte Herzensangelegenheit. In diesem Jahr ist sie es gleich aus mehreren Gründen: Nachdem die Ehrungen in den letzten Jahren aufgrund der Corona-Beschränkungen nur im kleinen Kreise stattfinden konnten, darf in diesem Jahr zum ersten Mal wieder im großen Rahmen gefeiert werden: Im neuen Rösler Betriebsrestaurant, welches 2021 am Standort Memmelsdorf / Untermerzbach eröffnet wurde. Bei der feierlichen Ehrung der verdienten Mitarbeiter bekam Stephan Rösler in diesem Jahr Unterstützung von seinen beiden Geschäftsführerkollegen Volker Löhnert und Oliver Grün. Letzterer wurde selbst für seine zehnjährige Betriebszugehörigkeit ausgezeichnet. Die Rösler Oberflächentechnik GmbH gratuliert … zum 40-jährigen Betriebsjubiläum: im Werk Memmelsdorf: Maria Zillig und Thomas Eberth. Beide sind dem Unternehmen nicht nur im selben Jahr, sondern als Lehrlinge auch am gleichen Tag beigetreten. Im Werk Hausen wird Detlef Griebel für vier Jahrzehnte Treue geehrt. … zum 25-jährigen Betriebsjubiläum: Eduard Fischer, Andreas Hentschel, Mario Jakob, Ralf Müller, Waldemar Riwe, Folkert Rothe, Steffen Schwab, Jens Siebensohn, Gerald Weiß, Katja Wohnig, Uwe Zörkler – alle tätig im Werk Memmelsdorf – sowie Ernst Hoffer, Peter Leipert, Rainer Schindhelm und Alexander Schröder im Werk Hausen. … zum 10-jährigen Betriebsjubiläum: im Werk Memmelsdorf: Norbert Wolf Dicker, German Gerstenlauer, Tim Gleichmann, Susanne Henkel, Christian Höhn, Martin Hopf, Kevin Kern, Kathrin Knöferl, Wolfgang Kroner, Marcus Mannel, Andreas Merz, Marco Schmittwolf, Arno Schneider, Holger Schwämmlein, Dominik Sperlich, René Stüllein, Sven Trier, Udo Weierich, Jennifer Weinland und Katja Weis sowie Katrin Fuchs, Oliver Grün, Ingrid Vetter und Yvonne Wagner im Werk Hausen. Nach langjährigem verdienstvollen Einsatz wurden Reiner Allert, Gerhard Edelmann, Uwe Fleischmann, Herwig Heiser, Imelda Hellmuth, Carola Jankowski, Wolfgang Panzer, Fredi Spangel, Martin Trutz, Theo Wirsching sowie Oswald Zöttlein in den Ruhestand verabschiedet. Kurs halten im Krisenjahr: Rösler hält an langfristigen Zielen fest Es war ein schwieriges Jahr mit vielen Unwägbarkeiten – dieses Fazit zog der Geschäftsführende Gesellschafter der Rösler Oberflächentechnik GmbH, Stephan Rösler, in seinem traditionellen Weihnachtsgruß an die Belegschaft. Man sei in den ersten drei Monaten gut gestartet, der Ukraine-Krieg habe dann aber vieles verändert – und die aufgrund der Corona-Krise ohnehin schon schwierige Lage an den Beschaffungsmärkten zusätzlich verschärft. Weitere Schwierigkeiten wie die Kostenentwicklung blieben aktuell, obendrauf kam noch die Energiethematik. Das im März 2022 abgelaufene Geschäftsjahr konnte die Rösler Oberflächentechnik GmbH zwar erfreulich mit einem unkonsolidierten Gruppenumsatz von rund 273,9 Mio. € und somit einem Gruppenplus von rund 16 Prozent abschließen und so die durch die Pandemie verursachte Umsatzdelle aus dem vorangegangenen Geschäftsjahr hinter sich lassen. Die Prognosen für das laufende Geschäftsjahr geben aber ein uneinheitliches Bild ab: So werden die Verfahrensmittel, Ersatzteil- und Serviceleistungen zwar weiterhin auf stabilem Niveau nachgefragt. Das Neumaschinengeschäft gestaltet sich allerdings schwieriger: Der russische Markt ist durch die Embargobestimmungen weggebrochen, außerdem ist durch die weltwirtschaftlichen Rahmenbedingungen insbesondere bei Großprojekten eine Zurückhaltung bei Investitionen festzustellen. Aus diesem Grund wird der Auftragseingang im Neumaschinenbereich zunächst unterhalb der Planungen liegen. Auch aufgrund einer Vielzahl getroffener Maßnahmen habe die Rösler Oberflächentechnik GmbH die zahlreichen Herausforderungen bisher aber „ganz gut bewältigt“, so Stephan Rösler weiter. An seiner langfristigen Ausrichtung gemäß der Firmenphilosophie Mission & Vision wolle das Unternehmen festhalten, zudem habe man 2022 trotz aller Schwierigkeiten einige wegweisende Projekte auf den Weg gebracht. Beispielsweise die Rösler Innowelt, ein umfassendes Konzept zur Umstrukturierung und Modernisierung fast des kompletten Bürobestandes am Standort Memmelsdorf / Untermerzbach. Langfristig erhoffe er sich auch durch zahlreiche Produktneu- und Weiterentwicklungen, die die Rösler Firmengruppe in den letzten Monaten auf den Weg gebracht habe, weitere Stärke, so Stephan Rösler. Im abgelaufenen Geschäftsjahr wurden ca. 5,6 Mio. € am Standort Memmelsdorf investiert und auch im laufenden Jahr werden weitere Investitionen in zukunftsorientierte Projekte an den deutschen Produktionsstandorten erfolgen. Seinen Mitarbeitern dankte der Geschäftsführende Gesellschafter für die tatkräftige Unterstützung und Loyalität im vergangenen Jahr. Trotz aller Schwierigkeiten konnte allen Beschäftigten das Weihnachtsgeld in voller Höhe ausgezahlt werden. Ein starkes Zeichen zum Ende eines Jahres, das aus vielerlei Gründen getrost als sehr schwierig bezeichnet werden darf.

Perfect de-flashing and dedusting of duroplast and thermoplast components at the production rate of the injection molding machine

Ever since ROS GmbH & Co KG was founded in 1926 the processing of plastic materials was always at the center of the company’s activities. Initially named Press plant ROS, the company now has a nearly 100 years old tradition in this field. Today the private business, managed by third generation family members, is a high-end partner for technically demanding injection molded components made from duroplast and thermoplast materials including polyphenylene sulfide (PPS). Product development, tool making, and production take place at the company’s headquarters in Coburg, Germany. An additional manufacturing plant is located in Ummerstadt in the German state of Thuringia. For removing the flashes on the components created by the manufacturing process the company has been working with Rösler shot blast equipment since 2006. Increase of the de-flashing shot blasting capacity Jürgen Bär, responsible for planning in the industrial engineering department at ROS in Coburg explains: „The demand for plastic components substituting metal parts, for example in thermo management systems for the automobile industry, has been rapidly growing. In 2021 this forced us to increase our shot blasting capacity at both our manufacturing locations. The plastic components reduce the overall weight of the cars and, therefore, help to reduce CO2 emissions. In addition, we received large orders for duroplast pre-formed components, among others from a leading manufacturer of garden tools“. After discussions with four suppliers of shot blast equipment the customer chose the wire mesh belt machine RSAB 470 and the swing satellite table machine RWS 1200 from Rösler. Jürgen Bär continues: „Deciding factors for choosing Rösler were our good experience with the shot blast machines we have been using for a long time, the compact, space-saving and sturdy equipment design and Rösler’s comprehensive knowledge in the field of plastic de-flashing. Moreover, we needed the continuous flow shot blast machine quickly. Rösler generously supplied a machine from their customer experience center within a few days“. Consistent and energy-efficient de-flashing in the tempering frame The flexible high-capacity shot blast machine RSAB 470 at the Coburg location is used for de-flashing of components made from duroplast and the high-performance thermoplast PPS-GF materials. After de-flashing the components undergo a tempering treatment. For this purpose, the components are placed on special frames. Normally the work pieces are placed individually on the wire mesh belt. To streamline the material handling operation and eliminate this time-consuming step, Rösler adapted the standard work piece transport system of the shot blast machine to the workflow at ROS. This re-design now allows placing the raw components on the tempering frames immediately after the injection molding process. The work pieces on the frames are then passing through the shot blast machine for the de-flashing operation and can, thus, be directly transferred to the tempering station. Four turbines, specially designed for plastic de-flashing and placed above and below the wire mesh belt, ensure consistent shot blasting results. This turbine arrangement allows throwing the media consisting of polyamide grains with a diameter of 1 mm onto the work pieces from above and below. Compared to the normally utilized suction air blast systems the turbines, equipped with electric drives, are considerably more energy efficient. Jürgen Bär adds: „Not only our certification per DIN EN 50001 demands a reduction of our energy consumption, but energy savings are also necessary to save costs and for reasons of sustainability“. A blast media flow control with automatic media replenishment ensures that there is always sufficient blast media available in optimal quality. The shot blast machine is equipped with numerous technical features such as the anti-static compound dosing system with automatic compound replenishment, the efficient air extraction from the blast chamber, the dual step parts cleaning system in the outlet zone and the effective blast media cleaning system with screen and air wash separator. All these features guarantee that the components coming out of the shot blast machine are perfectly de-flashed and absolutely clean. Since the plastic materials used at ROS and the polyamide blast media can cause explosive dust, the shot blast machines were equipped with special, ATEX-compliant filter systems. Fully automatic and sustainable de-flashing of single work pieces The swing satellite table machine RWS 1200 was installed to increase the shot blasting capacity at the plant in Ummerstadt. It is used for de-flashing components made from PPS-GF and outer dimensions of up to 163 mm. In line with the production cycle of the injection molding machine up to four work pieces are de-flashed simultaneously within a processing time of 40 seconds. The RWS 1200 has two chambers, equipped with four rotary satellite stations per chamber and each satellite holding one work piece. This clever design allows to unload/load work pieces in one chamber, while the work pieces in the other chamber are processed. Unproductive idle times are, therefore, minimized. One energy-efficient blast turbine throws the media onto the work pieces placed on the rotary satellite stations arranged in the shape of a diamond. The satellites are not only rotating but, depending on the work piece geometry, can also be stopped at a certain angle. Work piece areas that cannot be reached by the media thrown by the turbine, are cleaned with special air blast nozzles. This suction air blast system is equipped with pressure control and a vertically moveable nozzle holder ensuring precise de-flashing. In addition to the vertical movement a linear positioning system allows to place the nozzles precisely in front of the work pieces. The nozzles are working in either oscillating or static mode. „To minimize the usage of compressed air, we are working with work piece specific PLC processing programs“, concludes Jürgen Bär. The RWS 1200 is also equipped with automatic replenishment devices for the blast media and the anti-static compound, an air extraction unit for the blast chamber and a blast media cleaning system. The family enterprise ROS Since 1926 the family enterprise ROS GmbH & Co. KG has been known for precision in plastic components. For more than 90 years leading companies in the automotive, medical engineering, electrical and other industries have placed their trust in this specialist for plastic components and its products. With around 300 employees at two locations in Northern Bavaria and Southern Thuringia the company designs and builds high-precision tools for processing high-performance plastic materials in its own tool-making shop. This guarantees that the functional components produced with these tools are of an extremely high quality.

Mass Finishing Work Piece Handling Series, Part 3 – Maintaining Wear Linings

Adequate wear linings are an important factor in ensuring work pieces are efficiently handled in a mass finishing machine. Along with the method speed of transfer as well as the media selection and separation, the condition of a machine’s wear lining factors into the quality of process results. Thick linings assist with work piece handling by providing a cushioning effect, yet thin or damaged wear linings allow unwanted knicks, scratches, and dings. With more than 80 years of expertise in surface finishing, Rosler can assist with all aspects of your mass finishing process including proactively eliminating potential work piece handling issues. Observing Machine Conditions Regularly checking the lining of your work bowl(s) and trough(s) for wear is one way to ensure parts don’t get accidentally damaged during processing. Inspecting linings consistently will help identify repairable issues before permanent damage to the machine occurs. To effectively finish work pieces, media must be matched to the specific finishing task and the initial state of a work piece. For example, media used for deburring/edge radiusing and surface grinding can be very abrasive. If not properly protected by a suitable wear lining, the steel construction of a work bowl would be completely worn through in a few hours by contact with the media and work pieces. Polyurethane and, to a certain degree, rubber are excellent lining materials providing wear protection for thousands of operating hours. Even these materials wear through and must be periodically replaced with a new lining. Small areas can be temporarily patched with Polyurethane Repair Kits until the unit can be removed and professionally relined. If a reline is required, only use a qualified reline supplier such as the lining shop at Rosler. Relines are available in different degrees of hardness (shore A) and different qualities. Always make sure that the lining material is suitable for your specific mass finishing process. More information about specifying liner materials is available in a previous blog post . Side-by-side comparison of a vibratory bowl before and after relining Maintaining Process Stability Checking your work bowl lining for wear and replacing it in a timely manner is essential for the stability of your mass finishing process as a whole. In addition to worn work bowls, failure to ensure a proper protective lining can create other problems including: Work pieces getting stuck in the machine and, therefore, jeopardizing the integrity of different work piece batches. Media, water, and process chemicals can leak from the machine if the metal processing bowl is worn through and holes or cracks appear. Severe machine malfunction can occur when media or parts can get trapped in worn spots during the separation phase when the finished work pieces are separated from the media. Damage to the work bowl that is beyond repair, causing unnecessary downtime and requiring costly replacement parts. A weakened bowl can crack and make the entire machine unusable. Check your bowl lining at least monthly for wear or rips. The areas around drains, the parts loading chute, and around the unload areas will see the highest wear and are especially crucial. The “nail test” makes checking the liner thickness easy. Push a nail through the liner until you hit the base metal and record the thickness of the liner. Keep track of the liner thickness over time to predict when you will need to replace your liner. Most liners are between 5/8 and 1 in (15-25 mm) thick. Plan to get your machine relined when the thinnest part of your liner is less than 1/4 in (6 mm) thick. Just as optimal media mix must be regularly monitored, so must the condition of a work bowl. If not, the entire process and downstream operations may suffer. The Rosler Way Maintaining adequate wear linings protects your work pieces, equipment, and overall mass finishing process. Contact us for mass finishing expertise and insight. The complete Mass Finishing Work Piece Series includes: Part 1 – Selecting the Best Work Piece/Media Separation Method . Part 2 – Preventing Drop Height Damage . Part 3 – Maintaining Wear Linings .

Rösler Smart Solutions: Digital management of the process water parameters – Better process understanding improves mass finishing results

In his very first diesel engine Rudolf Diesel used already springs from the Siegmund Scherdel wire drawing company founded in 1889. Since then the company has evolved into a globally active operation that deals with forming, assembly and joining technologies as well as surface treatment. In addition, the company is also active in the manufacture of tooling and equipment. With 32 facilities around the world Scherdel actively supports its customers with services that range from initial briefings to volume production. The result are premium products that are not only used in the automotive industry but also in medical and electrical engineering as well as power generation. The products include stamped and bent parts, lock washers and components for electric vehicles. The latter are produced at the Scherdel Waldershof GmbH & Co. KG in Waldershof, Bavaria. The components made from different steel alloys, stainless steel and non-ferrous metals frequently receive their final surface finish in mass finishing operations. Besides the basic finishing tasks like deburring and edge radiusing, clean surfaces with a high degree of cleanliness are an important requirement. Clean surfaces are essential for conducting a proper optical quality control. In this context the quality of the process water plays a key role. Process water cleaning and recycling – for complex mass finishing applications At Scherdel Waldershof the process water from the mass finishing operation is cleaned and recycled with a semi-automatic centrifuge. However, to date the process water quality was only controlled by a daily check of the compound concentration. And this was usually done by different people who had little understanding and knowledge of the intricacies of the process water cleaning and recycling operation. „The process water gets contaminated by oil from the stamped & bent parts, belt lubricants and metal and media fines. On the one hand this increases the conductivity, which can cause faulty readings during the optical controls. On the other hand, the guidelines regarding particle size and quantities were not always followed. All this resulted in costly rework and even scrap parts“, explains Tobias König, department manager for mass finishing & cleaning at Scherdel Waldershof. Digital process water management results in transparency and generates knowhow When Rösler suggested to him to test the digital process water management system “Advanced” from Rösler Smart Solutions as a pilot user, the department manager immediately agreed. This new software package for semi-automatic and fully automatic centrifuges allows the user-friendly monitoring, recording and evaluation of all essential process parameters. These are: The compound concentration (measured by titration or refraction index – BRIX), pH value, conductivity, water hardness, microbiological contamination by bacteria, yeast and fungi, chloride content, COD value (chemical oxygen demand), BIT content (biocides in the process water), appearance and smell. Depending on the particular requirements for a given mass finishing process, the respective process parameters can be individually selected. In the “Advanced” version of the digital system the water samples are manually collected and analyzed with suitable measuring equipment that can be supplied by Rösler with the software package. The determined values are also entered manually. Based on the entered data the algorithm in the software develops recommendations for immediate corrective actions so that deviations from the specified values for the respective process parameters can be corrected and, thus, ensure process stability. Besides the recommendations for immediate corrective action the software also provides information that explains the adverse effects on the work piece surface, if the various parameter deviations are not quickly corrected. Since all data are recorded, they can be retrieved and displayed in the form of tables and time charts. This helps prevent costly downtimes by unplanned process water changes and allows to schedule such changes for time periods when they are less disruptive. „When Rösler presented the digital process water management system, we immediately recognized its potential for more transparency and a higher process stability. In addition, we realized that the recommended corrective actions along with the respective background information can be a tremendous educational tool that helps to increase the process knowledge of our employees“, concludes Tobias König. Increased process stability and improved finishing quality Scherdel Waldershof uses the digital process water management system with a semi-automatic Rösler centrifuge, model Z 800. This centrifuge cleans and recycles the process water from a Rösler mass finishing vibrator (model R 620) running in 3 shifts. The system controls the compound concentration and the pH value once per shift. A conductivity measurement takes place once per week. The microbiological contamination is checked whenever required. For example, this is the case, when the regularly monitored appearance and smell of the process water indicate that there might be a problem. The department manager explains: „The measurement and recording of the parameter values is easy and simple. We need about the same time for measuring and recording the compound concentration and the pH value as before.” He continues: „However, today we automatically receive an easy-to-read evaluation and a list of corrective actions that can be immediately implemented. This is a valuable tool to keep the process water stable and maintain a consistently high part quality. We have seen a reduction of rework and scrap parts by up to 50 %.“ The digital system issues not only recommendations for corrective actions when the parameters deviate from their rated values. Similar actions are proposed in case of events affecting the part quality and downstream manufacturing operations like corrosion, excessive foaming during the mass finishing process and insufficient cleanliness of the work pieces. To eliminate such problems the digital system issues detailed background explanations along with the recommended corrective actions. Tobias König concludes: „Most of the employees in my department have no special knowledge regarding mass finishing and handling of the process water. However, with the recommended corrective actions they not only learn what needs to be done, but they also acquire valuable process knowledge. This helps them understanding the relationship between the process water quality and the quality of the finished work pieces.“

Testing & Expertise Overcome Shot Blasting Challenges

For nearly a decade, Sales Representative and Interim Product Manager of Turbine Blast Equipment Zack Murray has been one of Rosler’s top shot blasting experts. Working with customers and our global Customer Experience Centers , he helps develop and test surface finishing machines and media in addition to dialing in specific process parameters. At times, adhering to the Rosler motto and guiding principle of “finding a better way…” can be difficult and complicated. Luckily, Murray and the entire Rosler team are committed to delivering world-class surface finishing equipment, consumables, and service in a variety of industries . In this post, Murray shares the most challenging issue he has tackled at Rosler and how the team developed a solution. The Problem A customer contacted Rosler for help in processing relatively large magnesium automotive parts. Considering the need for high throughput speeds in combination with the size of the parts, Murray knew a turbine blast machine would be the best option. Shot blasting turbine “In turn, the indication of a turbine blast machine meant that we were limited to metallic blast media,” Murray said, “as these machines are not typically suitable for mineral-based blast media such as aluminum oxide or glass beads. “Magnesium is a tricky material to blast in a turbine machine since it is prone to sparking with most metallic media. In addition to the fact that magnesium dust is highly flammable and combustible, we needed to avoid a potential recipe for disaster.” The process had to safely and efficiently deliver deburring and edge radiusing while minimizing the potential for sparking. The Solution Understanding that a relatively soft metallic media was required for safety and effectiveness, the team was left with the choice of aluminum or zinc blast media. Testing both media types demonstrated that results from the aluminum media most closely aligned with the customer’s desired process results. “Unfortunately, aluminum dust is also highly flammable and combustible,” Murray said. “The combination of the magnesium and aluminum dust was potentially dangerous enough to warrant an St3 Dust Hazard rating, which is the most severe rating, indicating a very high potential for fire and/or explosion. “Since the customer was not at a point in their product development cycle where they could get a dust hazard analysis performed as a result of part availability, we had to assume that the dust would be rated at St3.” As such, a wet dust collector with an anti-oxidizing compound dosing system was suggested for the customer with the further recommendation that the dust collector be installed outside, away from areas that commonly see human traffic, and that exhaust air was absolutely not allowed to feed back into the building. Rosler RF 550 NS including sludge drag conveyor and high-efficiency design to reduce residual dust The Rosler Way With more than 80 years of experience and a portfolio containing more than 15,000 equipment and consumable products, solving challenges is what we do at Rosler. Testing for safety and efficiency is an important step in achieving a stable and repeatable surface finishing process. Contact us today to request free test trials in one of our global Customer Experience Centers and allow us to develop a solution for your unique challenges!

Blade Technology: Straight vs. Curved Blades Explained

As an expert in the shot blasting industry, Rosler knows about blade technology. All shot blasting machines require blades to propel media towards workpieces. While both straight and curved blades are used, each type offers advantages and disadvantages. What are the Differences? Straight blades are, as the name suggests, blades that do not have curvature when viewed from the side and do not possess tangential curvature with respect to the turbine. Curved blades are blades that have some degree of curvature when viewed from the side. As the newer design, curved blades are generally better than straight blades, but they also have some drawbacks related to longevity, maintenance, and cost of ownership. Wear Rates Historically, the largest disadvantage of the curved blade design is that the blade will wear at a disproportionate rate along the length of the curvature, meaning that the curved blade design would wear through quicker than straight blade design. Modern technology has allowed the industry to overcome this particular flaw through the careful selection of curvature angle of the blade based on blade material properties to the point that curved blades now have similar usable lives to straight blades. Change Out Times A further disadvantage that has historically plagued the curved blade design is that the shape of the blades and fixturing take longer to change out than straight blades. The Rosler Gamma G turbine with forged metal blades overcomes this issue through the use of a retaining pin allowing for rapid blade change outs . This problem still currently persists for hard metal blade designs. Cost The final disadvantage is that curved blades tend to be more expensive than the straight blade designs, depending on the blade material. For cast and forged blades, the price difference is relatively small; however, for hard metal machined blades, the cost difference can be quite significant. Advantages Despite the disadvantages, curved blades also offer advantages over traditional straight blades. The largest advantage that the curved blades offer over straight blades of equivalent size is that the curved blades have a greater radial component to their velocities while maintaining an equivalent tangential component. This provides a higher throwing speed of the blades on the media (at equivalent turbine rotational velocities and equivalent turbine diameter) and therefore greater impact energy being transferred to the workpiece, allowing for the removal of more severe contaminants. Alternatively, if greater impact energy is not needed, the turbine’s rotational velocity can be controlled via a variable frequency drive to slow the turbine down which, in turn, provides a greater media throughput at equivalent media throwing speeds when compared against a straight blade turbine. Curved blade designs function at their best when the parts have very difficult finishing requirements or when greater part throughput is necessary. Orientations Curved blades have two types of orientation that can be used: a γ (The Greek letter gamma) shape and a C shape. The C shape has a greater curvature angle, allowing for a greater velocity/energy efficiency; however, the γ shape blade has a blade longevity factor in that once one side has been worn down, the blade can be flipped for a second use, effectively doubling the blade’s life. This is also an advantage over most straight blade designs. C-shaped blade Furthermore, the C shape does not have the ability to utilize a retaining pin for rapid blade changeout . The curvature angle of the blade (and therefore the blade's velocity and energy gain in comparison to a straight blade design) provides an equivalent lifetime based off of the material properties of the blade, namely its metal hardness. For modern metals, a cast blade can support a nearly negligible curvature without severely impacting its life, while a forged blade is capable of supporting a curvature angle that provides approximately a 7% increase in velocity (approximately 15% increase in energy) and a hard metal machined blade supports a curvature giving up to approximately 15% increase in velocity (approximately a 32% increase in energy) (utilizing a C shaped blade for maximum gain). The Rosler Way You can count on Rosler to help you find a better way when it comes to blade technology. Contact us today to discuss your unique challenges so we can identify the right blade for your needs.

Sauber Technologies continues pursuing technological innovation as it extends partnership with AM Solutions, a brand of the Rösler Group

Sauber Technologies has extended its technology partnership with AM Solutions – 3D post processing technology, a brand of the Rösler Group, taking a further step forward in the field of technological innovation. The partnership, which was sealed in 2021, has been prolonged for two additional years, as a logical consequence of a valuable and trustful business relationship that has been providing both parties with excellent results. Automated post processing of additive manufactured parts is essential for Sauber Technologies for the economical production of repeatable and high-quality printed parts, especially on an industrial scale. Over the last year, the company benefited from Rösler's decades of experience in surface finishing, by using post processing equipment provided by its brand, AM Solutions – 3D post processing technology. Several 3D printed parts have also been featured on the Alfa Romeo F1 Team ORLEN C42, bringing the strategic partnership from the factory to the track. Under AM Solutions – 3D post processing technology, the Rösler Group bundles all activities related to additive manufacturing with an outstanding range of products and services, including systems, consumables and process engineering for the series-ready and automated post processing of additively manufactured parts. Rösler's many years of cross industry experience in surface finishing in a real production environment as well as its own mechanical engineering form a strong backbone of AM Solutions offerings. As part of the relationship between Sauber Technologies and AM Solutions, the two partners are currently collaborating in the field of SLA (stereolithography) in post processing, to develop solutions to maximise the efficiency of the cleaning process and support removal, a further milestone in surface technology. In addition, Sauber Technologies is already using several mass finishing and shot blasting machines from AM Solutions. Christoph Hansen, COO Sauber Technologies: “Over the past year, the partnership with AM Solutions has been of fundamental importance, as several business practices of our Group have been employing them, from the wind tunnel models to the most experimental components, and, of course, our Formula One cars. AM Solutions have brought their excellent experience and solutions to Sauber Technologies, helping us creating 3D printed parts faster and in a more efficient way, two essential qualities for an ever-evolving business like ours. I am glad to be extending our partnership with the Rösler Group, and I am already looking forward to seeing what else we could achieve together in the future.” Volker Löhnert, Managing Director of Rösler Oberflächentechnik GmbH: "The extension of our partnership with Sauber Technologies is an important milestone for AM Solutions – 3D post processing technology. The team has a long tradition of using additively manufactured components in its Formula One cars and has been therefore interested in exploring the vast opportunities that 3D printing offers in terms of design, material selection, and lightweight construction. High-quality and repeatable post processing is of great importance for the optimization of the entire process chain, and that is where we bring our decades of expertise in surface finishing, together with our customized solutions developed specifically for the peculiarities of AM-manufactured parts. For these reasons, we have the perfect partner at our side in Sauber Technologies."

Husqvarna relies on intelligently linked Rösler equipment

In its chain link production Husqvarna is utilizing three Rösler FKS 35.1 A2-So centrifugal disk finishing machines along with a fully automatic Z1000 process water cleaning centrifuge. For over 10 years these machines have reliably handled highly demanding finishing processes in a 24/7 manufacturing environment. Because of this outstanding track record and the excellent cooperation Husqvarna called on Rösler to provide technical assistance with a capacity expansion project. The company installed an additional centrifugal disk finishing machine with convincing new technical features and a second automatic centrifuge equipped with the software package “digital process water management” developed by Rösler’s Smart Solutions team. The seamless integration and intelligent linking of the new with the already existing equipment made the production of chain links more flexible and more cost-efficient. Above all, it resulted in a higher overall stability of the finishing operation. Elimination of capacity bottlenecks in the surface finishing operation Prior to the expansion and modernization project the centrifugal disk finishing machines were assigned to specific mass finishing processes. The strict assignment was intended to prevent the mixing of different process liquids and, thus, facilitate the process water cleaning operation. However, this rigid organization of the centrifugal disk finishing machines did not allow their flexible use. For this reason, the available finishing capacity could not be utilized in a cost-efficient manner and caused frequent manufacturing bottlenecks. To provide more flexibility, the new centrifugal disk finishing machine is equipped with a dual dosing unit allowing the machine to be connected to two process water recycling systems. This allows running different finishing processes in the same machine. In combination with the new process water cleaning centrifuge and the resulting increased cleaning capacity the finishing machines can now be flexibly assigned to the actual processing jobs without affecting the overall surface finishing quality of the chain links. Innovative technical features increase the process stability and reduce the cycle times The new centrifugal disk finishing machine is equipped with a custom-engineered work piece loading system. In addition, the special design of the processing bowl offers a higher working volume. But that is not all: Special flow guide segments along with anti-slip bars, a special spinner design and an increased drive power ensure a much better mixing of the work piece batches weighing several hundred kilograms. All this brought about a higher finishing intensity with shorter cycle times, increased the overall productivity and produced more consistent finishing results. Husqvarna was also impressed by the fully automatic adjustment of the gap between spinner and processing bowl. Manual gap adjustment and time-consuming gap measurements could be completely eliminated. The “intelligent” control system is automatically setting the gap to a size that matches the work pieces to be processed. Moreover, the control system continuously monitors the gap size during the entire finishing process and automatically adjusts the gap as needed. Rösler is the only company that offers such an advanced gap control system! Of course, with this sophisticated technology even very thin work pieces cannot get stuck in the gap. This prevents premature wear and potential machine crashes. Besides a much higher process stability the automatic gap control also increases the equipment availability by eliminating the time required for manual gap adjustment. Complete process control and traceability The purchase order from Husqvarna also included the linking of the mass finishing machines with a subsequent manufacturing operation. It covered not only the transfer of processing programs and process data but also the integration of the finishing machines into the existing Manufacturing Executive System (MES) at Husqvarna. This ensures not only a complete process control but also the monitoring of the equipment status and the finishing parameters. Digital process water management – up to 50 % lower water usage and longer uptime of the process liquid The process water cleaning process at Husqvarna is quite demanding. Therefore, the company was pleased to integrate the digital process water management system from Rösler Smart Solutions into its modernized process water cleaning and recycling operation. This innovative, interactive monitoring system for semi- and fully automatic centrifuges allows the monitoring, collection and evaluation of all essential process parameters. Suitable problem-solving recommendations are automatically issued. This helps to significantly reduce the water consumption and increase the uptime of the process water resulting in considerable cost savings. Based on a preliminary analysis the time periods between process water changes could be extended by 50 %. The resulting increase of the process water uptime also amounts to about 50 %. On-time completion of this challenging project The capacity expansion and modernization project could be implemented within a tight and quite challenging time frame. Despite the current supply chain difficulties Rösler not only met the agreed upon delivery date but could commission the equipment at Husqvarna two weeks earlier. Rösler Smart Solutions – Improved surface finishes and lower reject The Rösler Smart Solutions system is also used at the Scherdel Waldershof GmbH & Co. KG. This company produces stamped and bent components as well as parts for the automotive industry from steel alloys, stainless steel and non-ferrous metals. The mass finishing operation requires not only excellent deburring and edge radiusing results, but the work pieces must also be perfectly clean for the subsequent optical quality control. The process water is cleaned with a semi-automatic centrifuge. In the past the somewhat limited quality control procedure for the process water checked only a few parameters resulting in unwanted media and metal residues on the finished work pieces. This required costly rework, before the components could be delivered to the customers. With the digital process water management from Rösler Smart Solutions the situation could be completely turned around. The well-organized data output and the easy-to-understand action points from the “digital guide” ensure that the process water remains stable at a high quality. In turn, this produces absolutely clean work pieces. With the digital process water management system the rework and scrap rate could be cut in half. Digital process water management improves process stability and increases cost-efficiency At the Wegmann Automotive GmbH, global leader in the field of balancing weights, the process water from the mass finishing operation is cleaned in a fully automatic centrifuge. In principle, the operator manages the water cleaning and recycling operation quite well. Nevertheless, the company decided to install the digital process water management system from Rösler Smart Solutions. Because of different technical requirements the company recently had experienced some difficulties. Weights made from steel receive a corrosion protection in the mass finishing process, while zinc components must have a specified surface tension for a subsequent coating operation. These different requirements led to either a too high or too low compound concentration in the process water, resulting in considerable rework and large quantities of scrap parts. The customer had not considered the consequences of a microbiological contamination. In this case the interactive digital process water monitoring system from Rösler Smart Solutions produced a much more stable process and drastically reduced the rework and scrap rate.

How to Use a Vibrascope to Measure Vibratory Bowl Amplitude and Frequency

When it comes to mass finishing , amplitude and frequency require balance and careful consideration. Amplitude is a measure of movement and intensity while frequency refers to the rate of repetition. The wrong amplitude, for example, can create lackluster finishing results and longer processing times if it is too low. If too high, it can cause unnecessary wear and tear on the machine. Creating Vibratory Energy Whether rotary or tub style , mass finishing vibrators always include two key components: a work bowl containing the finishing media and the work pieces. Firmly attached to this work bowl is a vibratory drive system generating the energy to put the media and work pieces in motion. The work bowl with an attached vibratory drive system sits on a number of coil springs – in some cases on air cushions – which in turn sit on a machine base. The springs, respectively, act as air cushions allowing the work bowl to “free float” up and down within a certain distance. Example of vibratory drive The force from the vibratory drive system moves the media and work piece mix within the work bowl. Depending on the type of finishing machine, this force is generated by vibratory motors or electric motors driving a shaft with one or multiple imbalance units attached to it. Imbalance units are made up of a rotating shaft with out-of-balance counterweights at each end of the shaft. Due to its imbalance, the rotating shaft causes an intense wobbling effect. Common drive systems in vibratory bowls and tubs include foot motors for small tub vibrators, flange motors for rotary vibrators, and multiple imbalance units with electric drives for large tub vibrators. The Effects of Vibration Since the work bowl with attached vibratory drive system is loosely sitting on the coil springs or air cushions, the energy induced by the vibratory drive system causes the work bowl to move up and down within a relatively narrow distance band at the speed of the rotary drive system. The maximum up and down displacement of the vibrating work bowl from its position of rest is an indicator of the vibratory intensity and is called amplitude. Measuring & Reading Amplitude Understanding your machine’s amplitude is part of the process to dialing in precise surface finishing results. The amplitude – actually the double amplitude from upper to lower peak – is mostly measured in mm. In finishing vibrators, the amplitude is usually between 3 and 6mm. Rosler uses a visual devise called a vibrascope, a sticker applied to the outside wall of the work bowl, to visually measure amplitude. This sticker contains a row of 7 circles with diameters from 1 to 7 mm. Example of Rosler's Vibrascope sticker The simplest way of reading the amplitude is by observing the vibroscope sticker as the machine is in operation. The vibration of the work bowl has the visual effect of showing two rows of circles, with some circles being completely apart and some overlapping. The two circles which are apart but nearly touch each other represent the observed amplitude value. Adjusting Amplitude The vibratory intensity or amplitude of a machine is determined by three factors. Adjusting one or more of these factors will adjust the resulting amplitude. Speed of the Vibratory Drive System – Higher rotary speeds produce higher amplitude. Mass of the Imbalance Weights – Heavier imbalance weights produce higher amplitude. Angle or “Lead Angle” Between the Two Imbalance Weights – Smaller angles produce higher amplitude. The highest intensity is produced at zero degrees, while the lowest – practically no vibration – is produced at 180 degrees. Rosler advises adjusting one factor at a time for the most accurate fine tuning as well as safety and longevity of the machine. The speed and amplitude in finishing vibrators cannot be increased beyond a certain value; otherwise the machine would destroy itself. The acceleration, consisting of rotary speed and amplitude must not exceed 6g. At high rotary speeds, the imbalance weights must be set for a low amplitude (mass of the imbalance weights and lead angle). At lower speeds, the imbalance weights can be set for a higher amplitude. The Rosler Advantage Machines built by Rosler run with more frequency and less amplitude, meaning our media contacts a workpiece more times and is gentler than competing machines. This unique advantage of Rosler equipment creates less wear on media and machines while producing greater longevity. The ability to reduce amplitude yet deliver the desired surface finishing produces less machine shaking and part damage while slowing the rate of machine wear. When using vibratory bowls and tubs, most of Rosler’s competitors hit harder. While impressive, the force of those hits may not produce the most efficient results. Finding the Right Settings In the above graph, the numbers highlighted in yellow are the optimal combination of amplitude and frequency. Amplitude settings depend on the machine set-up, workpiece condition, and desired outcome. Not sure what amplitude is best for your unique needs? Trust the experts at Rosler to conduct a trial and dial in the results before you purchase a machine. The Rosler Way Whatever your mass finishing needs are, you can count on Rosler to help you find a better way. Contact us today to discuss your unique challenges and request a free trial in one of our Customer Experience Centers .

New Deflashing Equipment Assists 30-year Customer Increase Production

For over 30 years, Berker GmbH & Co KG (Berker) has trusted Rosler shot blasting equipment in its manufacturing processes. A member of the Hager Group since 2010, Berker is one of the leading manufacturers of high-end electrical components, from timeless classical switches to intelligent electrical systems for buildings. The company also supplies switches for electrical appliances and automobiles. The Situation Berker primarily uses continuous feed systems such as loop and flat belt machines to deflash plastic components including switching elements, electrical outlet covers, frames, and more. Increased production volume at its Wenden-Ottfingen manufacturing location led Berker to decide to invest in an additional shot blast machine in 2018. The new investment was intended to replace an existing continuous feed loop belt system with the latest deflashing technology. Its specifications called for increased capacity and high equipment availability. The Solution After the capacity requirements had been established, Rosler developed a system concept that fully met the customer’s technical and economic demands known as the RSBS 1702 continuous feed loop belt blast machine. Equipped with two direct-drive blast turbines , the new Rosler machine produces excellent deflashing results combined with an extremely high degree of process stability. The machine includes a host of technical features including modern PLC controls, an optimized media cleaning and recycling system with a vibratory screen and air wash separator, a sensor-controlled media replenishment unit, automatic replenishment and mixing of anti-static compounds, noise protection, an automatic standby module, and a dust collector. The new machine design also allows the automatic deflashing of large work pieces which could not be handled with the old equipment and has been in operation since 2020. The Advantages Rosler is grateful to have the opportunity to assist a 30-year customer achieve new efficiencies even in the midst of a global pandemic and labor shortage. Automated aspects of Berker's new system went beyond improved efficiency and capabilities to provide an additional advantage in the reduced need for manual labor. Like many employers, Berker has faced increasing competition for manpower. The use of work piece handling systems, conveyor belts, and robots have helped bridge the gap in human resources and maintain production rates. Additionally, in the world of manufacturing, this mitigation of human intervention offers even greater and more measurable efficiencies and consistent quality. The Rosler Way “Finding a better way…” is more than a motto at Rosler; it’s our mission. With more than 80 years of experience and a portfolio containing more than 15,000 equipment and consumable products , solving challenges is what we do. Contact us to learn how we can help you achieve more efficient, automated surface finishing.