Installation and Construction Plan for the Rotary Table Blast Cleaning Machine
I. Project Overview
This project involves the installation and construction of a rotary table blast cleaning machine. The equipment is mainly used for rust removal, oxidation layer removal, and enhancing the surface texture of various metal workpieces. It is widely applicable to surface cleaning operations of castings, stampings, mechanical parts, and other workpieces. The rotary table blast cleaning machine adopts a rotating table to support the workpiece and a fixed-point blast cleaning structure. It features high operational efficiency, uniform cleaning, good sealing performance, and high automation level.
The construction content of this project includes the recheck of the foundation for the rotary table blast cleaning machine, the cleaning chamber of the main unit, the rotating table mechanism, the total assembly of the blast cleaning device, the hoist, the separator, the dust removal system, the electrical control system, the powder circulation system, the pipe connection, the overall machine commissioning, the trial run, and the final acceptance. The core goal of this construction is to strictly follow the equipment installation specifications, ensure the installation accuracy and operational stability of the equipment, and guarantee that the quality of workpiece cleaning, dust emission compliance, and the safety protection system meet the production requirements after the equipment is put into use.
II. Construction Preparation for the Rotary Table Blast Cleaning Machine
(1) Technical Preparation
1. Organize construction technicians and operators to fully understand the equipment drawings, installation parameters, and technical specifications, sort out the installation sequence of each component, precision requirements, and key difficult processes, and clarify the construction technical standards.
2. Conduct special technical briefings and safety briefings, clearly define the construction responsibilities of each position, operation procedures, quality control points, and key points of safety risk prevention, ensuring that all personnel master the construction requirements.
3. Verify the equipment installation foundation drawings with the on-site baseline, determine the equipment installation center line, elevation benchmark, and prepare a special construction schedule, reasonably arrange the construction procedures.
(2) Site and Foundation Preparation
1. Clean the construction site, level the working area, remove debris, water, and oil, ensure the smoothness of the lifting, transportation, and construction operation channels, and divide the equipment placement area, operation area, and safety warning area.
2. Foundation recheck: Check that the concrete strength of the foundation meets the design requirements, there are no cracks, hollowing, or settlement defects; verify the foundation elevation, center line, anchor bolt hole position, and size, with deviations controlled within the allowable range of the specifications; clean the debris and water in the bolt holes to ensure the foundation is flat and solid, meeting the equipment bearing requirements.
3. Reserve space for equipment operation and maintenance, plan the installation positions of the dust removal system outlet, electrical control cabinet, and adapt to the on-site pipeline layout.
(3) Equipment and Material Preparation
1. Count each component, standard part, sealing part, and electrical accessory according to the equipment packing list, check the specifications, quantity, and appearance without deformation, damage, rust, and ensure that the accessories are complete and intact, make a record of the count.
2. Prepare installation-required steel materials, sealing glue, fireproof sealing materials, grounding materials, etc., all materials quality should comply with the construction specifications.
3. Prepare powder in advance, select the equipment-appropriate specification steel powder, ensure there are no impurities, lumps, and meet the test machine production requirements.
(4) Equipment and Personnel Preparation
1. Construction Tools: Equip with truck cranes, hand winches, levelers, theodolites, tape measures, torque wrenches, electric welders, hand drills, wire strippers, etc., all tools should be calibrated and in good performance; ensure that the safety protection equipment is complete and effective.
2. Personnel Configuration: Equip with project managers, technical leaders, safety officers, quality inspectors, certified electricians, fitters, hoisting workers, etc., all personnel should hold certificates and have corresponding construction operation experience.
III. Construction Installation Process of the Rotary Table Blast Cleaning Machine
Overall construction sequence: Foundation re-measurement and leveling → Installation and fixation of the main unit → Installation and debugging of the turntable mechanism → Installation and calibration of the abrasive blasting unit assembly → Installation of the hoist and separator → Connection of the projectile circulation system → Installation of the dust removal system pipelines → Wiring and connection of the electrical system → Sealing treatment of the entire machine → Single-machine no-load debugging → Linked load debugging → Rectification and optimization → Completion acceptance.
(1) Foundation re-measurement and main unit positioning
1. Use level gauges and theodolites to precisely re-measure the elevation, center line, and flatness of the equipment foundation, and perform leveling treatment on the foundation surface. Parts with excessive deviations should be ground and corrected in time.
2. According to the equipment installation reference line, lift and position the cleaning room main unit, adjust the levelness and verticality of the main unit, with the horizontal deviation of the body ≤ 0.5mm/m, and the overall verticality meeting the design requirements.
3. Install the anchor bolts, evenly tighten the bolts, fix the main body of the machine, ensure no tilt or shaking, uniform force, and recheck the horizontal accuracy after the fixation is completed.
(2) Installation of the turntable mechanism
1. Clean the contact surface of the turntable base installation, remove oil stains and rust, precisely position and install the turntable base, fix the base bolts, ensure the base is level and firm.
2. Install the main shaft, bearings, and turntable surface of the turntable, adjust the gap of the turntable to ensure the surface is flat and the rotation is flexible, without jamming or deviation.
3. Install the turntable drive motor and reducer, calibrate the tension of the transmission chain/belt, fix the protective device, and test-run the turntable rotation to ensure uniform speed and stable operation, without abnormal noise or vibration.
(3) Installation and calibration of the abrasive blasting unit assembly
1. Assemble the abrasive blasting unit according to the assembly sequence, successively install the bearing seat, main shaft, coupling disc, impeller body, blades, divider wheel, directional sleeve, etc., all bolts are tightened according to the specified torque to ensure the components are closely attached and firmly installed.
2. Fix the assembled abrasive blasting unit at the preset installation position of the cleaning room, seal the installation interface to prevent powder leakage.
3. Precisely adjust the angle of the directional sleeve window, calibrate the abrasive blasting throwing direction, ensure that the powder can evenly cover the cleaning area of the workpiece without blind spots or off-target throwing, ensuring the quality of workpiece cleaning from the source.
(4) Installation of the hoist and separator
1. Install the frame and shell of the bucket hoist, adjust the verticality of the frame, tighten the fixing bolts, install the hoist hopper, conveyor belt, adjust the tension of the conveyor belt, ensure smooth operation, no deviation, no slipping.
2. Install the sand and projectile separator, connect the discharge port of the hoist with the inlet port of the separator, make the interface sealed to prevent powder and dust leakage.
3. Adjust the wind selection air volume and screen gap of the separator to ensure thorough separation of sand and projectiles, effectively screen out impurities and waste projectiles, and ensure the qualified projectiles are recycled.
(5) Installation of the projectile circulation system
1. Install the powder collection device at the bottom of the cleaning room and the conveying pipeline, connect to the discharge port of the hoist, ensure smooth and tight pipe connections, no powder leakage or accumulation死角.
2. Check all pipe interface and flange connection points, install sealing gaskets, tighten connection parts, and prevent powder leakage and dust spillage during operation.
3. Sort out the powder circulation path, ensure smooth operation of the collection, lifting, separation, and throwing throughout the process, without blockage hazards.
(6) Installation of the dust removal system
1. Position the dust removal equipment according to the drawings, make the installation height of the dust removal equipment compatible with the pipeline layout, place it stably and firmly.
2. Install the dust removal pipelines, the slope of the pipeline ≥ 3°, to avoid powder accumulation and blockage; the connection of the pipelines is tight, the overall leakage rate ≤ 5%, all flange interfaces are equipped with sealing gaskets, the weld seams are full and without leakage points.
3. Connect the dust removal outlet of the cleaning room with the dust removal pipeline, fix the pipeline support, perform dust removal pipeline anti-corrosion treatment, ensure that the dust removal air volume matches the equipment operation conditions, and meet the requirements of environmental protection dust removal.
(7) Installation of the electrical control system
1. Install the electrical control cabinet and operation console, ensuring they are firmly fixed and reliably grounded. The horizontal and vertical deviations of the cabinet body should comply with the specification requirements.
2. Lay out the power cables and control cables, arranging them neatly and securely tied. Take measures to protect the cables and prevent damage or exposure. Ensure the wiring is standard, the terminals are tightly pressed, and the markings are clear. The strong and weak electrical systems should be separated.
3. Install the emergency stop switches, limit protection, overload protection, and alarm devices for safety electrical components. Improve the grounding and zero connection protection system of the equipment. The grounding resistance should meet the technical requirements of the equipment.
4. After completing the wiring of the electrical system, thoroughly check the lines, identify and eliminate the risks of incorrect connections and missing connections. Conduct insulation tests and ensure the safety and reliability of the electrical system.
(8) Sealing treatment of the entire machine
Carry out sealing treatment on the door panels of the cleaning room, observation ports, inspection ports, interface of each pipeline, and equipment gaps. Use special sealing glue and sealing gaskets to seal the gaps, preventing projectiles from flying out and dust from spilling out, to ensure a clean working environment and safe operation of the equipment.
IV. Commissioning and trial operation of the rotary table shot blasting machine
(1) Pre-commissioning inspection
1. Conduct a comprehensive inspection of the installation firmness of each mechanical component, ensuring that the bolts are not loose and the components are not misaligned. The transmission mechanism should be flexible and smooth, and the protective devices should be complete and intact.
2. Check the connection of the dust removal, circulation, and electrical systems, ensuring that the pipes are unobstructed, the lines are correct, and the lubrication system is filled with qualified lubricating oil and grease.
3. Clean the internal debris and tools of the equipment, confirm that there are no remaining obstacles inside the equipment, and ensure that the conditions are ready for commissioning.
(2) Single-machine no-load commissioning
1. Start each single-machine equipment one by one, test the operation status of the shot blasting machine, lifting machine, rotating platform mechanism, and dust removal motor. The no-load operation time of each single machine should be no less than 30 minutes.
2. Check the operating current, temperature, and speed of each motor. The equipment should operate without abnormal sounds, vibrations, or jams. The transmission mechanism should run smoothly.
3. Test the sensitivity of the buttons, switches, and PLC programs of the electrical control system, and ensure that the emergency stop, limit protection, and overload protection functions are effective and reliable.
4. Check the equipment seals and pipeline interfaces. Confirm that there is no air leakage or pellet leakage. After the no-load commissioning is without abnormalities, proceed to the linkage commissioning.
(3) Whole-machine no-load linkage commissioning
Start the automatic operation program of the entire machine. All systems should operate in linkage. Run continuously for 1-2 hours. Observe the overall operation status of the equipment throughout the process to ensure smooth connection of each process, precise operation, no faults, no jams, and stable operation parameters that meet the standards.
(4) Load test commissioning
1. Add 1/3-1/2 of the rated capacity of qualified steel balls to the equipment and place standard workpieces for test blasting operations.
2. Observe the cleaning effect of the workpiece, adjust the angle of the directional sleeve of the shot blasting machine, the flow rate of the pellets, and the rotation speed of the rotating platform to optimize the cleaning parameters. Ensure that the rust removal grade of the workpiece reaches Sa2.5 level, the surface cleaning is uniform, without missed blasting or over-blasting defects.
3. Test the operation effect of the dust removal system, check that the dust emission meets the environmental protection standards, and there is no dust spillage. Record the operating current, temperature, noise, etc. parameters to ensure they meet the design standards.
4. Run continuously for 2-4 hours under load. The equipment should operate stably, the fault alarm should be normal, and all indicators should meet the standards. This is considered as the commissioning qualified.
V. Quality acceptance standards
1. Foundation and body: The equipment foundation is flat and solid, without settlement or cracks; the horizontal and vertical degree deviation of the body complies with the specification requirements, firmly fixed, without shaking or deviation.
2. Mechanical system: Each transmission component operates smoothly, without abnormal sounds or vibrations, the rotating platform rotates flexibly, the shot blasting machine works normally, the pellet circulation is smooth, without blockage or leakage.
3. Dust removal system: The pipeline is sealed tightly without air leakage, the dust removal effect is good, the dust emission meets the environmental protection standards, and there is no dust spillage during equipment operation.
4. Electrical system: The wiring is standard, the markings are clear, the insulation performance is qualified, the protection devices are sensitive and effective, the control system operates stably and is easy to operate.
5. Cleaning Effect: The surface of the workpiece is uniformly cleaned, rust removal and oxide layer removal meet the standards, and there are no cleaning blind areas, which meets the production process quality requirements.
6. Overall Machine Performance: The equipment starts and stops smoothly, the linkage is reliable, and there are no faults during long-term operation. All running parameters comply with the factory design standards of the equipment.
Six. Safety and Civilized Construction Measures
(1) Construction Safety Measures
1. Set up safety warning signs at the construction site, strictly prohibit irrelevant personnel from entering the operation area. For high-altitude operations and lifting operations, strictly abide by special safety regulations and wear complete safety protection equipment.
2. Electrical operations are carried out by certified electricians. Strictly prohibit connecting wires under power, illegal operations. The temporary electricity is set up in a standardized manner, and proper rain protection and leakage protection are implemented.
3. During the hoisting and transportation of the rotating disc shot blasting machine, unified command is given, and the operation is carried out smoothly to prevent equipment from colliding and deforming, and to prevent personnel from getting injured. Violations of regulations and risky construction are strictly prohibited.
4. During the debugging operation period, personnel are strictly prohibited from approaching the equipment operation parts. When conducting trial runs, start the equipment gradually, and immediately stop and cut off power when abnormalities are found to investigate and eliminate them. Do not allow the equipment to operate with faults.
(2) Civilized Construction and Environmental Protection Measures
1. At the construction site, materials are placed categorically and neatly, and construction waste is promptly cleared to keep the site clean and orderly.
2. During the construction process, control dust and noise, and the dust removal equipment is debugged in advance to reduce construction dust and noise pollution.
3. After the construction is completed, promptly clean the equipment and site debris, ensuring that the work is completed, materials are exhausted, and the site is cleared.
Seven. Completion Acceptance and Document Archiving
1. After the construction is completed, conduct self-inspection and re-inspection by oneself, identify and rectify construction defects, confirm that the equipment meets all indicators, and then apply for joint acceptance by the owner and the supervisory unit.
2. The acceptance content includes installation quality, equipment operation performance, cleaning effect, safety protection, environmental protection indicators, etc. After passing the acceptance, sign the completion acceptance record.
3. Compile a complete set of construction documents, including technical briefing records, equipment inventory records, installation inspection records, debugging records, acceptance reports, and the drawings and specifications of the rotating disc shot blasting machine, and archive and retain them for project delivery.