Deflashing Machines for Industrial Use

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There are many good reasons why companies all over the world rely on Rösler deflashing technology.

The Hunziker® trademark is synonymous with technologicalleadership in the industrial deflashing of thermoset and highly filled thermoplastic mouldings. These machines aredeveloped and produced by Rösler Schweiz AG, whichmaintains a world-wide sales and servicing organization.

We offer our customers innovative products and services,comprehensive processing expertise and a sound understand-ing of system interrelations.

Our strength lies in user-oriented solutions that ensure maxi-mum quality and efficiency for our customers, giving them that crucial competitive edge. You benefit from an extensiverange of single-source deflashing machines for thermosetmouldings and for the semiconductor industry. Our portfolioranges from simple, manually operated machines to fullyautomated interlinked systems. Thanks to their high deflashingperformance, the machines can also be used to treat (deflashand clean) magnesium, zinc and aluminum die-castings.

Tell us what your requirements are, and our development and test center will work out the economically and technicallymost suitable solution.

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Blast-wheel and blast-gun coverage in comparison

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Deflashing systems

Process Technology

Deflashing medium reconditioning

Blast gun technology

Contrary to blast wheels, blast guns areused for applications in which deflashingis desired in defined locations only, or inwhich only small quantities of deflashingmedium are required. Blast guns areused in combination with blast wheelsto deflash areas difficult to access, e.g.for the deflashing of bores or pockets.

Blast wheel technology

To accelerate the deflashing medium tothe high velocity required for efficientdeflashing, it is most common to useblast wheel technology. Blast wheelsaccelerate the deflashing medium byexploiting the centrifugal force.Compared with blast guns, their specificenergy consumption is very low. Blastwheels provide the high coverage desir-able for most applications.

Screening unit

Multi-stage screeners and/or airflowseparators continuously remove flash,flash particles, fibers and spent deflash-ing medium from the deflashing mediumbeing circulated within the machine.

Automatic, sensor-controlled replenishmentof consumed deflashing medium ensuresconsistency in deflashing medium quality(operating mixture).

Cascade separator

A cascadeseparatorcontinuouslyremoves flash,flash particles,fibers and spentdeflashing mediumfrom the circulatingdeflashing medium.

Deflashing medium replenishment

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Dust collector/dust extraction Antistatic systems Safety features

Control unit

– Electronic control system with centralmonitoring

– Status and malfunction indicators– Compliance with the relevant CE

standards– Easy to install, with plug-in connec-

tions between the machine and thecontrol unit

Component cleaning

Cleaning/blow-off of the deflashedcomponents is tailored to the type ofcomponents in question.

EMERGENCY STOP switch

Safety monitoring

To prevent dust from re-depositing on thedeflashed components due to staticcharges, all our machines are equippedwith an antistatic fluid spray system.Antistatic fluid contained in a tank issprayed into the deflashing chamber via nozzles. As an alternative to themanual water/antistatic metering unit,we also offer an automatic metering system (connection to water mains,selection of mixing ratio via the OP).

Cyclone separator

«Vital features ensure the quality consistency and process reliability necessary for thermoset deflashing.»

Design with blower

Design with compressed air

Exhaust air is freed of dust by special,highly efficient filter cartridges. An auto-matic backcleaning system for the filtercartridges (the machine need not behalted) permits 24-hour operation.

Extraction from the deflashing zone

Dusty air is extracted from the deflashingchamber. Depending on the applicationin question, various methods are used torecover serviceable deflashing mediumand return it to the process.

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Bulk deflashing machines

SBSK loop belt machines

The components are transported to theloop belt of the deflashing machine viaa feed conveyor and a vibrating feedchute. The special (rubber) loop belt isconstructed as a screw conveyor withturnover cams, and permits transport ofthe components at a defined speedthrough the deflashing zone. The com-ponents are deflashed by way of one

RMBC tumble belt batch machinesKey features Loop belt machines

1–3 blast wheels, continuous operation

For the automatic bulk deflashing of– large volumes– small to medium-size components

Typical applications:– Housings, covers and sockets for

electrical installation material– Housings and covers for circuit

breakers and contactors– Pan handles– Ashtrays

or more blast wheels under which thecomponents are transported and turnedcontinuously. The components are then freed of anyadhering deflashing medium in an inte-grated exit drum, where they continue tobe turned. The components dischargedfrom the machine are largely dust-freeand ready for subsequent operations.

Plastic components that can be tumbledare processed batchwise in a compactdeflashing machine with one blastwheel. An endless perforated rubberbelt conveyor limited laterally by rotatingdisks forms a deflashing chamber thatcan accommodate a maximum work-piece load volume of 30–100 dm3.The movement of the tumble belt turnsthe workpieces continuously during thedeflashing operation and then frees themof any adhering deflashing medium.

View into the loop belt trough(metal profile) for small parts

Operating principle of the SBSK machine

RMBC 05.1-S

SBSK 1201

View into the loop belt trough(lamellar-type rubber elementsfor gentle component transport)

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WTS 2201

sides. A given distance is maintainedbetween individual components toprevent them from touching each otherand becoming damaged. More robust components are supplied to the machine in bulk via a feed con-veyor with a hopper.

WTS principle

The tunnel deflashing machines weredeveloped primarily for the deflashing ofthin-walled and fragile components. The tunnel transport system advancesfragile components successively and ata defined speed through the deflashingzone, turning them over continuously toensure that they are deflashed from all

WTS 2302

WTS Tunnel machines

Key features WTS tunnel machines

1–2 blast wheels, continuous opera-tion

For the automatic deflashing of– fragile, medium-size components

in succession– less fragile components in bulk

Typical applications:– Meter housings and terminal strips– Fragile switch components– Iron handles and other handles

of complex shape– Terminal housings– Multiple covers– Fragile miniature circuit-breaker

housings

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Through feed deflashing machine type SAB 470-SK

Key features SAB conveyor machines2 – 8 blast wheels, continuous orindexing operation

For the automatic deflashing of – small to high volumes– small to large-size components– delicate components

Typical applications:– Components made from unsaturated

polyester moulding compounds(BMC/SMC), such as headlightreflectors, meter housings and otherlarge-area components

– Components for irons, oven door handles

– Switch housings and covers, fragileminiature circuit breaker housings

High-performance blast wheel technology

Deflashing medium reconditioning viacascade separator

SAB 470-SK 2+2

Feed inlet area / wire mesh conveyor

Conveyor machines

Deflashing chamber with component holders

The SAB 470-SK 2+2, a high-perform-ance deflashing machine with 4 blastwheels, is suitable for the continuousdeflashing of large volumes of thermosetmouldings. Two blast wheels above andtwo below the conveyor system ensureintensive and uniform treatment.Additional advantages of the machineare easy maintenance due to the blastwheels being located outside thedeflashing chamber and efficient clean-ing and reconditioning of the deflashingmedium. The deflashing medium iscleaned via a vibratory screening unitthat removes flash and undersizeddeflashing media, and reconditionedvia a cascade separator.

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High-performance conveyor machines for automated manufacturing

SAB 300-S4 conveyor unit with magazine

For fragile components that are insertedindividually into the magazine by a handling system or robot. Photo: Machine with four blast wheelsfor deflashing up to 4800 miniature circuit breaker housings per hour.

Compact conveyor machine type SAB 370-SK

These high-performance conveyormachines are typically used to treat verythin-walled, fragile housings that must onno account be damaged. The machinescan be equipped on all sides with threeto five blast wheels of different sizes.Such machines are used, for instance, in production lines with fully automatedworkpiece removal from several injec-tion moulding machines, pre-deflashing,calibrating/gauging and routing to thenext processing stage, e.g. deflashing,assembly and packaging.

Conveyor unit with component-holder system

For fragile components that are placedindividually onto a component holder bya handling system or robot. Conveyorsystems from different manufacturers canbe used. The machine is used for a wide rangeof comparable component types.

The Hunziker® SAB 370-SK conveyorunit is a small and compact machine that offers the same advantages as thelarge machines of this series.

– Belt width 370 mm– Alternatively one or two blast wheels

located above and below theconveyor

– Vibratory screening unit– Continuously adjustable parameters– PLC control system– Requires little space

SAB 370-SK 1+1

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Manufacturing cells

WS 1200 swing table deflashing machine

A deflashing machine intended specifi-cally for the gentle deflashing of diversethermoset mouldings and for variablecapacities in one and the same machine.In a dual-step operation involving aswing table, the mouldings are deflashedindividually or in groups on 2 oppositesatellites. While one satellite is beingloaded or unloaded, the parts on theother satellite are deflashed. The modu-lar system permits different configura-tions to suit individual requirements.Depending on the type of components,two methods are available for the fullyautomated blasting and deflashingprocess – blasting with injector nozzlesfor very selective deflashing, or theeconomical blast-wheel system. Thesatellites can be equipped with holdingfixtures for up to 6 parts.

The deflashing machine can be integratedsmoothly into a manufacturing cell with-out compromising operational safety. For example, in instances where differ-ent parts are produced in one or moreinjection moulding machines or by com-pression moulding and then have to bedeflashed automatically

Key features WS 1200 swing table deflashing machine

Deflashing machine that can beequipped alternatively with 1–2 blastwheels or up to 8 blasting nozzles.

For automatic deflashing of – delicate components in a manufac-

turing cell– an entire mould cavity

Variable equipment for the stations:– one turntable per station– rotating satellites for 1 – 6 part-

holding fixtures per station– satellites mounted in the direction

of rotation

Integrated in a manufacturing cell

WS 1200 with blasting guns

Deflashingchamber withblasting andblow-offnozzles

WS 1200 withblast wheel

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SAS 1400 turntable unit

As a rule, turntable units are designedfor the processing of a particular work-piece with an individual degree ofautomation. For this reason the SASseries is based on a modular system that permits economical solutions bothfor manual feeding, semi-automatic andfully automatic operation. Linearly oper-ating vertical and horizontal nozzle-mov-ing devices increase the degree ofautomation in the units. The SAS turntable unit can be tailoredto the customer’s requirements by way offurther accessories such as a separateair-wash separator, pressure blastingequipment or handling devices.

Key features SAS turntable units

for up to 10 blasting guns, the tableis turned incrementally, for manualfeeding, semi-automatic or fully-auto-matic operation.

For the deflashing of – small to medium-size components– delicate components

Typical applications:– Engine covers– Pump housings and wheels– Suction manifolds– Thin-walled miniature circuit breaker

housings– Brake pistons

Blasting stations for manual or automatic deflashing

Blasting cabinet of various sizes

RWT-S 1000: Deflashing machine for 1–2 satellites per station and dual-step-opera-tion. Can be equipped with up to 6 blastingnozzles. Various options available.

«Manual or semi-automatic operation, or fully automated manufacturing cells? We have the right solution for every application.»

ST blasting cabinet with perforated platform

Turntable with satellites

ST blasting cabinet with rotary basket

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Semiconductors

SAB 40/3000 lead-frame deflashing machine

The lead frames are loaded continuous-ly onto the machine’s belt conveyor. The conveyor transports the lead framesthrough the deflashing chamber betweenthe suction blast guns mounted on either side of the conveyor. Cams on

Loading module Unloading and restacking module

The loading module serves for automatic,successive loading of lead frames frommagazines (buffer magazines suppliedby the customer) onto the belt conveyor.The module is equipped with additionallead-frame storage capacity so as topermit smooth and continuous operationwhile an empty buffer magazine isbeing replaced.

The unloading and restacking moduletransfers the lead frames dischargedfrom the machine into an empty maga-zine.

Automatic loading and unloading

Exit zone with blow-off system

SAB 40/3000

the conveyor prevent the lead framesfrom slipping on the conveyor. The leadframes then pass through a blow-offzone where air jets remove deflashingmedium still adhering to the leadframes.

Key benefits

– Proven, high-capacity machinedesign for fully automatic operationand early payback (ROI).

– Low-maintenance, dry deflashingsystem, little force exertion thanks to use of low pressures, consistentlyoperating suction blast guns, littlewear and easy operation

– System capacity of up to 1800lead frames per hour

– Precise edge-to-edge deflashing,with masking where required to prevent damage to plastic packaging

– Adjustable guide rails to accommo-date lead frames of various dimen-sions

– Suitable for all deflashing mediatypically used in this application,such as thermosets, polyamides and other plastic deflashing media,natural deflashing media derivingfrom nutshells or fruit stones, pow-dered brass, etc.

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Machine construction

For special demands of the processingenterprises Rösler constructs and buildsin addition to the standard series alsospecial machines.

Additional equipments

ST blasting cabinet with satellites

Feed conveyor

WSA 2000 with sliding gate

All Rösler machines can be adapted and individually automisedwith an extensive offer of standardequipments. Available are: – Feed conveyors– Transport conveyors– Handling systems– Pre deflashing units– Ionization plants – Dust collector – etc.

Exit drum moveable

Special machines and supplies

SKI 1200 with rotary basket

Roboblaster

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Service

Consultation Quality Spare parts and warehouse

Before they leave our factory, all ourdeflashing machines are subjected tocomprehensive testing. As a rule, theyare tested with the customer’s compo-nents that were used earlier during trialruns. Ideally, the customer is present forthe preliminary acceptance test so as to witness the perfect quality of thenew deflashing machine. Flexibility: Should changes in customerrequirements or new insights necessitatealterations to the machine at short notice,these can be implemented before themachine is delivered. Customer wishesin respect of transport and installationare also discussed at the time of the preliminary acceptance test. Our experienced technicians and processengineers are available for purposes ofinstallation, commissioning and training,as well as for servicing and mainte-nance.

The necessary deflashing, or postwork-ing, of thermoset mouldings is a factorto be considered right from the designstage. Suitable mould design, in parti-cular, can prevent the occurrence ofparting lines that either cannot bedeflashed at all or else will leave visibletraces. Consultation and close coopera-tion with both component and moulddesigners is therefore essential. If com-ponents cannot be automatically andcompletely deflashed following their fabrication, secondary finishing costswill arise that are out of all proportion to the production costs.

As a system supplier for thermosetdeflashing, we have a large stock ofspare parts and can provide majorcomponents ex-warehouse.

Test center

At our test center in Switzerland we havethe appropriate machine systems for con-ducting tests with your thermoset mould-ings. Why not send us some samplecomponents for a test or visit us at ourfactory and judge the results for yourself –on site.

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Antistatics and deflashing media

Deflashing mediaThe wide range of potential applica-tions calls for a correspondingly largenumber of different deflashing media.Long service life, low wear and theshortest possible deflashing time are key requirements imposed on the media.

Ongoing comparative tests, deflashingtrials and scrutiny of the media in on-siteinstallations ensure constant refinement

and are the reason that what was oncea simple «ancillary medium» has nowbecome a major factor in reducingcosts.

Also we can supply you with the mostsuitable deflashing media. Our deflash-ing machines can be operated with thefollowing deflashing media.

– Polyamide (PA), cubical or cylindrical– Polycarbonate (PC), cylindrical

– Filled polyamide deflashing media forspecial applications

– Natural products from nutshells or fruitstones (cherries, apricots, etc.)

– Powdered brass– Thermoset material

Various antistatics can be used, depending on the application andconditions:– Tween 20– Neutrostat B– Destatic RDST II

Consumables

Antistatics

16Surface Finishing · Shot Blasting · Engineering · Environmental TechniquesRÖSLER Schweiz AG

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Rösler Schweiz AGStaffelbachstrasse 189P.O. Box 81CH-5054 Kirchleerau/SwitzerlandPhone +41 62 738 55 00Fax +41 62 738 55 80info@rosler.ch

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