Rösler helps Pratt and Whitney to enhance part finishing processes

“Our shot blasting concept optimises process control as it is a closed loop system which measures and allows for adjustment of key process variables and requires less input from operators, meaning greater efficiency and cost savings.”

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Rösler UK has been working with Pratt and Whitney to replace a robot shot blasting system that has been used to prepare surfaces with intricate features of rotating components ahead of plasma spray application of coatings. The previous system also had a focus on optimising process controls.

This type of technology is essential for the aerospace industry when it comes to preparing and finishing the surfaces of metal parts and components. The system propels abrasive materials at high speeds to clean, strengthen and polish metal surfaces to rid them of any defects.

“When looking to replace the old robot shot blasting system at the Christchurch Engine Centre, an aviation maintenance, repair, and overhaul centre, Pratt and Whitney were interested primarily in a system that would give them better process control and which would ultimately lead to consistent results in respect of surface texture and therefore coating adhesion,” said Tony Pugh, Aerospace Projects Manager at Rösler UK. “Our shot blasting concept optimises process control as it is a closed loop system which measures and allows for adjustment of key process variables (KPVs) and requires less input from operators, meaning greater efficiency and cost savings.”

Having a closed-loop system can ensure accurate measurements and adjustments of KPVs whilst also reducing waste and negative environmental impacts.

Pugh continued, “The KPVs Rösler’s shot blasting system measures and adjusts for Pratt and Whitney’s solution including blast media flow, air pressure, air volume, blast nozzle distance and angle to workpiece, blast grit size, all backed up with predictive maintenance messages and prompts. All of this control, together with machine and process status, is presented to the operators and management via our unique PC Supervisor, Windows-10-based system, which also stores all process data per part number and easily interfaces with Manufacturing Execution Systems.”

Pratt & Whitney’s shot blasting system is primarily used to treat rotative aerospace components which are often featured in intricate designs where complex geometries and tight tolerances are required. Additionally, as these components must be used in aerospace settings, they need to deliver extremely high performances and efficiency levels, especially in high-speed rotations.

Additionally, all components must be uniform, with intricate details preserved whilst also strengthened. To fulfil Pratt & Whitney’s requirements, Rösler utilised ABB robots in the aerospace OEMs shot blasting system, and incorporated robot studio and offline programming for greater flexibility. This resulted in users gaining optimised ergonomics, as well as improved safety and access to conduct maintenance operations.