Knowledge and information are indispensable for the efficient organization and optimization of business and production processes. We at Rösler consider it as essential to periodically inform our customers and partners about new solutions and developments in the field of surface treatment. Exactly for this reason and because of our firm commitment to organize our processes in a sustainable manner, we have digitized our Chip customer magazine and decided to publish it twice a year.
Digitization is a subject we have been focusing on for quite a while in our mass finishing and shot blasting products as well as in our own production. In the future digitization will play an even more important role in our company. The central aspect of our digitization strategy is to deliver excellent quality, provide the best service and become more innovative. All this serves the goal to offer added value to our customers. Our strategy also extends to the development of mass finishing consumables to ensure the optimal interaction between machine, grinding/polishing media and compound and to fulfill special customer requirements with individualized solutions. Our Customer Experience Centers around the world and our global service organization are staffed with local specialists. They support our customers in the development and optimization of their shot blasting and mass finishing processes to make sure that these processes are becoming part of an efficient manufacturing system. Our local experts are also doing maintenance work, repairs and equipment modernizations. In addition, we offer technical support for resolving mass finishing issues, either in person or through video calls. Please read more about this subject in our latest edition of Chip.
Last but not least, our Rösler Academy offers hands-on seminars and webinars covering numerous topics in the fields of mass finishing, shot blasting, additive manufacturing and Lean Management. In many companies these training events have become an essential tool for expanding the professional knowledge of their employees. The Academy program is an important part of our comprehensive and unique service portfolio.
“Additive Manufacturing is changing the world. Is this just a vision or already real?” AM Solutions - 3D post processing technology shines a light on these and other interesting questions in its new, interactive live event series “inside AM”. In this, representatives from renowned companies, active in different industrial sectors, will provide a valuable behind the scenes glimpse and report about their experience, applications, visions and obstacles that must be overcome.
We hope that our latest solutions and the unique Rösler product and service portfolio find your interest! We look forward to tackling new and interesting challenges in close cooperation with you. Please enjoy reading the first digital edition of our Chip magazine.
With best regards,
President and CEO
To offer the highest quality, to provide the best service and to be more innovative – these are the highlights of Rösler’s comprehensive digitization strategy. Through its implementation the company actively promotes the digital transformation for its mass finishing and shot blasting products as well as for its own manufacturing operations. By creating the brand Smart Solutions Rösler acknowledges the importance of this trendsetting technological transformation. While it takes place across all industrial sectors, digitization is still at its beginning in the field of surface refinement. Of course, all developments in this field are entirely driven by the requirements of the market. The goal is to allow quick correction of equipment faults on the basis of transparent processes and active operational monitoring that generates corrective proposals. On the basis of archived data, digitization will allow the implementation of intelligent process and equipment controls, which will ultimately result in substantial cost savings. At the same time, consumption and wear predictions, along with an optimal utilization of resources, will help to maximize the equipment uptimes and will create added value. The digital approach will also allow the complete documentation of all relevant equipment and process parameters. For example, such documentations are mandatory in the automotive, aerospace and medical engineering industries.
Digital process water management for mass finishing operations
The first product developed by the Rösler Smart Solutions team for mass finishing deals with the process water cleaning and recycling with centrifuges. This is an operation that is highly critical for achieving good finishing results, but because of its numerous process parameters it is somewhat difficult to handle by its users.
The digital process water management system allows the measurement, data entry and control of up to 14 process parameters by an interactive monitoring system. It helps to control parameters such as compound concentration, pH value, conductivity or bacterial infection. The dashboard displays all relevant equipment and process data and proposes specific corrective actions, if any of these parameters are out of their pre-determined range. Therefore, problems and equipment faults can be quickly detected and preventive measures for restoring the process stability can be immediately undertaken. This helps to minimize unplanned equipment downtimes for process water exchanges. Such exchanges can take place at a time, when the operation does not have to be interrupted. Since all parameters are stored in the system, the data can be displayed in the form of diagrams and tables. This facilitates their analysis.
With its user-friendly setup and absolutely safe operation the new digital process water management system represents an important milestone towards improved process stability and maintaining a high process quality. In turn, this results in excellent finishing results. At the same time, the system helps save valuable resources and improves the sustainability of the manufacturing operations. We are pleased to report that, because of its numerous customer benefits, the new process water management, available since April 2021, is already in use at several customers.
Besides the further refinement of the digital process water management system, Rösler Smart Solutions is also developing other innovative solutions for the digitization of the actual mass finishing process as well as for the shot blast equipment range and the products of AM Solutions – 3D post process technology. Among other tools we also foresee the use of artificial intelligence (AI). In this field several patent applications have already been filed.
Optimized manufacturing through digitization
The comprehensive digitization strategy at Rösler also covers its own administration and manufacturing operations. This includes the extensive automation of processes in order to achieve the highest possible process stability and consistency. For example, this was achieved by the utilization of welding cobots. With a 100% consistency they produce absolutely even, exact welding seams in the automatic production of turbine housings at a considerably lower energy consumption. Also, a cloud based solution allows easy access to important welding process data. Another example is the relief of employees from tedious, non-productive internal logistical tasks. For quite a while Rösler has been using driverless autonomous pallet trucks. A precise control system allows them to pick up pallets with material and transport them to a high-bay warehouse, where they are automatically placed at pre-determined storage locations. Or they will quickly transport material from the warehouse to specific shop floor locations.
With all these measures and other ongoing digitization activities Rösler is taking important steps towards becoming more efficient, improving the quality of its products and further increasing the customer benefits.
Europe is rapidly switching over to electric vehicles. According to the association of European automobile manufacturers, in the year 2020 394.943 new electric vehicles were registered in Germany. This represents a more than three-fold increase over the previous year. A similar trend can be observed in France, Great Britain, Norway and Sweden. This rapidly growing demand for vehicles with alternative drive systems is causing the OEM’s and the suppliers to significantly expand their manufacturing capacities. However, completely new and re-designed components, revised manufacturing technologies and different materials require innovative surface refinement technologies. To meet these challenges in a fully automated production environment, Rösler, as a competent partner of the automotive industry, has developed suitable technical solutions. These include innovative shot blasting and mass finishing processes as well as the post processing of 3D printed components. Among other manufacturers, BMW is taking advantage of the latest Rösler equipment solutions
De-sanding and deburring of stator carriers within a cycle time of 50 seconds
The Landshut plant of the BMW group is a good example for this trend: The fully automatic production of stator carriers includes a shot blasting process for the de-sanding and deburring of different versions of these aluminum castings. The shot blasting operation takes place in a RWK 6/12-2 swing chamber shot blast machine.
The work pieces arrive on a conveyor belt from a de-sanding station, where most of the molding and core sand is removed from the castings. A robot placed in front of the shot blast machine picks up one stator carrier at a time and places it on the custom-engineered work piece fixture in the load/unload chamber of the shot blast machine. After the work piece has been loaded, a protective cover is placed over the matrix code that was already inserted during the casting operation. Then the chamber rotates by 180 degrees. This allows the robot to remove an already shot blasted stator carrier from the chamber and placing it in a staging station for transport to an intermediate storage location.
Design features such as the dual chamber design of the shot blast machine and the utilization of two high-performance 15 kW Gamma 300G turbines made it possible to meet the cycle time target of maximum 50 seconds. In comparison to traditional turbines the Gamma 300G units achieve an up to 20 % higher blast performance with an, at the same time, lower energy consumption. Another valuable feature of these innovative turbines is that both sides of the throwing blades can be utilized, which practically doubles their usable life. A quick-change system allows replacing the throwing blades without having to dismount the turbine from the housing.
Digitization facilitates operating the equipment
In close cooperation with an automation specialist the Rösler engineers developed a digitization package that makes the operation of the machine efficient and intuitive. This includes a visualization of the shot blasting operation at the equipment HMI allowing adjustments of the turbine parameters during the shot blasting process. Moreover, if necessary, the work piece position in the blast chamber can be corrected, thus eliminating any equipment downtimes for manual setup operations. All these features, combined with a predictive wear part management, have significantly increased the equipment uptime. Therefore, the initial higher expenses for the digitization package will be amortized very quickly.
Compact, fully automatic casting-shot blasting manufacturing cell for die-casters
In cooperation with renowned manufacturers of casting cells Rösler developed a solution for casting and shot blasting in combination with robotic work piece handling. For example, such a space saving casting/blasting cell is in operation at an automotive supply company, who invested in a manufacturing cell for the production of complex aluminum die-cast components for vehicles with BEV-, PHEV- and mHEV drives. This application also uses the RWK 6/12-2 swing chamber shot blast machine. Equipped with two Gamma 300G turbines, it can handle components with a height of up to 1,200 mm and a diameter of up to 600 mm.
B+S offers a broad spectrum of job shop services such as mass finishing operations for deburring, polishing and cleaning, shot blasting and packaging. In its function as a job shop the company serves customers from a variety of different industries. Therefore, it is not surprising that B+S has to deal with a broad range of work pieces with different shapes and sizes, made from different materials and requiring different finishes. To ensure continued excellent quality and on-time deliveries in a cost-effective manner, this service company is counting on well-trained employees and utilizes modern equipment and consumables from Rösler.
The best equipment technology as an essential key for success
The B+S Metallbearbeitung GmbH was founded by Herbert Bickel in the year 1959. At that time the company focused primarily on mechanical surface treatment such as mass finishing. In 1991 Mustafa Sahin became an employee of the company located in Murr in Southern Germany. Since 2004 he held a 50% share in B + S. When he became the sole general manager in 2007, he recognized that in order to remain successful, the outdated equipment had to be replaced with modern machinery. Furthermore, to strengthen the company’s competitive position, he decided to expand the service portfolio. An important aspect of this expansion strategy was to be able to process the customer’s work pieces safely and consistently and to use high-quality equipment that could be operated round-the-clock.
Service portfolio expanded by shot blasting and work piece cleaning
Irrespective of the first negative effects of the financial crisis, in 2008 the entrepreneur invested in a shot blast machine to expand his service package. In this case Mr. Sahin decided to also purchase Rösler equipment. „I assumed that the quality of the shot blast equipment was comparable to the excellent quality of the mass finishing machinery. Through intensive consultations and the deep knowledge about shot blasting we could gain through our discussions with the Rösler experts, we determined that a continuous flow shot blast machine was the right product for us,” reports Mustafa Sahin. A major characteristic of the shot blasting process is that the equipment is subject to considerable wear. Therefore, a good technical service with short turnaround times were key factors in the decision for Rösler. „As a job shop we cannot afford long wait times for a service engineer and spare parts,” adds the general manager. Through the continuous expansion of its shot blasting job shop services, in the meantime B+S Metallbearbeitung has purchased six additional shot blast machines. The general manager continues: „Generally, shot blast equipment is subject to significant wear. Therefore, depending on how intensively they are used, we are selling our shot blast machines after 3 to 5 years as used equipment. This allows us to always be technologically up-to-date and to offer our customers the best possible results at competitive prices.
With the work piece cleanliness requirements becoming more demanding, the company took advantage of another opportunity to expand its service portfolio. Mustafa Sahin reports: „In numerous conversations with our customers we learnt that many companies wanted to outsource the cleaning of their work pieces and that they were looking for a reliable job shop for this service. We found that work piece cleaning was an excellent opportunity to expand our surface treatment activities.” After comprehensive research and a thorough market analysis the customer chose a water based cleaning system from Rösler. The work piece cleaning operations are taking place in conjunction with mass finishing, shot blasting, a 100% quality control and/or packaging. But the cleaning services are also offered separately. In the meantime, work piece cleaning has become a core competency of the company and will be further expanded. In this respect the general manager is looking for a cooperation with a laboratory specializing in cleanliness analytics that will assist him to prove that the cleanliness demands for certain cleaning jobs have been met.
A market position that has been achieved by quality, flexibility and taking calculated risks
With its philosophy to react to the individual customer requirements with excellent quality, a high cost efficiency and on-time deliveries B+S has successfully established itself in the market. In the meantime renowned companies from various industries, such as car manufacturers and automotive suppliers, machinery building companies, furniture manufacturers, medical engineering companies, as well as foundries and stamping companies are relying on the services offered by the jobshop. The company handles work pieces made from aluminum, steel, stainless steel, magnesium, copper, brass and plastic components. The decision to utilize modern finishing technologies, high-quality equipment and consumables and the courage to invest during difficult times are certainly one reason for the success of B+S. Mustafa Sahin concludes: „Our success in the field of mechanical surface treatment depends on the right equipment, the best consumables and knowledgeable partners who can inform us about the latest developments and provide a comprehensive knowledge transfer. We get all this from a single source, namely Rösler.”
Questions and problems around mass finishing processes must be resolved irrespective of existing contact and travel restrictions. For this reason, the department for technology applications and process engineering has expanded its service package. Besides the on-site technical advice – whenever this is possible – and technical support over the phone the customers will now also be able to receive support through online meetings.
During these virtual events questions regarding equipment and consumables can be answered with the help of live video streams. This online service is also available for resolving such problems as foaming during the finishing process, corrosion of the work pieces, media lodging in the work pieces or poor separation of the finished work pieces from the media after the finishing process is completed. Following the slogan that a picture is worth more than a thousand words, the video call allows the comprehensive depiction and discussion of equipment and process details by smart phone or tablet. With such virtual meetings it is also possible to display possible solutions regarding media selection or suitable separation screens and to discuss their practical use. Even during the currently challenging circumstances the new service will allow us to resolve individual questions and problems in a fast and efficient fashion.
Additive Manufacturing replaces numerous traditional manufacturing processes, facilitates the development of new products and business models and helps establish new value-added and supply chains. Are these claims about the possibilities of Additive Manufacturing real, and in which industries have they already been successfully implemented? What is really feasible, to what extent are businesses already using 3D printing, and what is the driving force behind this development? AM Solutions shines a light on these and other interesting questions in its six-part live event series “inside AM”. In this series, representatives from renowned companies, active in different industrial sectors, will provide a valuable behind the scenes glimpse and report about their experience, applications, visions and obstacles that must be overcome.
Design freedom, light-weight construction, efficient resource utilization, cost and time savings, these are some of the keywords that are frequently expressed in conjunction with Additive Manufacturing (AM). Add to this the potential effects on established logistical systems, the need for personnel to drop traditional engineering philosophies and the potential to individualize products and adapting them to the wishes and requirements of the consumers to an extent, so far thought impossible. Does this mean that Additive Manufacturing is changing the world? Are these things really true, and what is the actual situation in the field of AM? How, and in which industries, are 3D printing technologies already used? And what is still just a vision? With its new interactive live series “inside AM” AM Solutions – 3D post processing technology, a brand of the Rösler Group that specializes on 3D post processing solutions, will answer many of your questions. It provides not only valuable information for the actual users of the 3D printing method but also for anybody interested in new technologies.
Interactive platform that offers valuable behind the scenes information
The live-streams are conducted in English and are accessible from anywhere in the world. Representatives from renowned companies, active in such diverse industries as medical engineering, aerospace, energy, automotive/motor sports and consumer products, will report about their experience with AM and will highlight the various aspects of this new manufacturing technology. Under the moderation of Georg Schöpf, editor-in-chief of a well-known AM magazine, the participants will provide valuable behind the scenes insights and will report on the actual status of Additive Manufacturing in their respective industrial sector and company. The interactive format of this event allows viewers from all over the world to participate in the conversation and pose their questions live to the respective participants. The event is broadcast live from the new Customer Experience Center of AM Solutions. Manuel Laux, Head of AM Solutions – 3D post processing technology, explains: „Anybody, who deals with the subject Additive Manufacturing, is probably overwhelmed by reports about the numerous innovative applications of this technology. With our interesting interactive event, we, jointly with our guests, want to shine a light on the question ‘Additive Manufacturing changes the world. Is this just a vision or already real?’ and provide information on the actual situation”.
Formula One and Sauber Engineering in the pole position
Guest at our first event is Christoph Hansen, Director Technology & Innovation at Sauber Engineering AG, a member of the Swiss Sauber Group. Internationally, this company is not only known through the Sauber-operated Formula One team, Alfa Romeo Racing ORLEN. The origins of the company stem from the demand to make racing cars faster, lighter and more reliable. Sauber tackled these challenging problems with Additive Manufacturing and, today, can be truly called a pioneer in this field. Christoph Hansen comments: „When AM Solutions presented this new discussion concept to me, I immediately liked the idea to look at Additive Manufacturing from different angles and from the view of different industries. It is honest and informative. I look forward to report to the viewers, how we started exploring the possibilities of AM, and how we expanded the use of this manufacturing technology beyond just the Formula One racing cars”.
The live stream with Christoph Hansen will be broadcast on Wednesday, June 9, 2021 at 3.00 PM (CET). Viewers can register free-of-charge under www.inside-am.com. The subsequent online live events will take place once per month. Exact dates and time will be communicated in due time. For the time being the participants of the next events are still kept a secret by the event organizers.