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News Release from: Rosler Oberflaechentechnik | Subject: Overhead rail shot blast system
Edited by the Manufacturingtalk Editorial
Team on 14 October 2005
Overhead rail shotblast system is
Europe's largest
Europe's largest overhead rail shot blast system has been installed at a German iron foundry to to clean and remove residual casting sand from wind power system components.
Iron foundry GGT- Grossguss Torgelow is one of several manufacturers of components used in wind power generation systems The company has invested in a new casting production line, specially designed to produce oversized cast components for offshore wind turbines
This article was originally published on Manufacturingtalk on 7 Oct 2005 at 8.00am (UK)
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For GGT's new production line, Rosler has developed a massive shot blast system to clean and remove residual casting sand from these components.
With about 16,500 onshore wind turbines and an output of nearly 16.5 gigawatt hours, Germany is the world's top generator of wind power.
In addition, the German wind power industry is rapidly expanding seaward.
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On German coasts, up to 25 gigawatt hours of wind power is planned to be generated by offshore systems by 2030.
Wind power is a growth industry throughout Europe.
The German Institute for Wind Energy forecasts that by 2008, 36GW hours of wind power will be available in Europe.
Today, German wind energy system and component manufacturers generate a higher proportion of the net product abroad than at home.
* A new casting production line - GGT-Grossguss Torgelow belongs to the group of manufacturers that produce components for the construction of wind turbines, as well as machine- and heavy equipment building and engine casting.
Components such as rotor hubs and base frames with high stress load must be cast to the highest quality specifications.
The process developed for this purpose by the iron foundry industry not only offers uniform quality results, but cuts costs as well.
This contributes to an increase in both the performance potential of the system's manufacturers, and the reliability and cost-effectiveness of the wind turbine systems, which is very important for offshore use.
Offshore systems are significantly larger than land-based systems.
Their larger size requires a corresponding increase in the production volume of rotor hubs and gear components.
* 42m overhead rail shot blast system - a Rsler continuous-flow overhead rail shot blast system was required to clean the cast components, up to 8m (26ft) in length and weighing up to 100 tons, and to remove residual casting sand.
This shot blast system is an integral part of the new production facility for oversized cast parts.
The shot blast system was planned correspondingly big and powerful-it is the only overhead rail system of its size in Europe.
The total system, including loading and unloading stations, measures 42m (138ft) in length, including an 18m (59ft) long shot blast cabin.
Different sizes and shapes of components can be treated.
This was the decisive factor for Rosler.
In order to ensure an economical continuous feed of the heavy parts, a tandem operation with two parallel-running, automatically controlled, cranes was developed.
Within the shot blast zone, there are three fixed crane positions.
A total of ten high-performance blast wheels operate at different angles to deliver highly efficient cleaning.
The entire shot blast system is designed to withstand very extreme production conditions.
The cabin is constructed of 8mm (1/3in) manganese steel and 12mm (1/2in) manganese plates.
The maximum noise level of the system is below 80dB.
As an all-round supplier, Rosler is an 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 of metals and other components.
Besides the German plants in Memmelsdorf and Hausen, the Rosler Group has branches in Great Britain, France, Italy, The Netherlands, Belgium, Austria, Switzerland, Spain, Brazil, South Africa and USA.
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