Aluminum Dross Processing using Yaskawa Robots

Industry > Metal·PlasticsApplication > Etc.Sector > Manufacturing

This automation solution utilizes YASKAWA robots to automate the hazardous manual process of handling high-temperature aluminum dross (a byproduct of molten aluminum).

By deploying a robot with high heat resistance, this system replaces human operators in extreme thermal environments, ensuring workplace safety and enabling continuous, non-stop operation. The primary goal of this project was to enhance operational safety and improve the work environment by automating the byproduct treatment following high-heat aluminum processing.

Components

Robot	Robot: YASKAWA MH180 High-payload 6-axis articulated industrial robot. Payload: 180kg (Ideal for heavy dross and robust heat-shielding) Reach: 2,702mm (Ensures safe distance from the furnace) Weight: 970kg Repeatability: ±0.2mm

Workflow

STEP 1.	Skimming: The robot scrapes and collects dross from the surface of the molten metal.
STEP 2.	Loading: The collected dross is picked up or scooped by the robot's specialized tooling.
STEP 3.	Unloading: The dross is transferred and unloaded into a dedicated discharge bin.
STEP 4.	Measurement: The system measures the fill level of the discharge bin.
STEP 5.	Discharge: Once the bin reaches full capacity, it is automatically transported to the external outfeed area.

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Key Features

Maximized Efficiency and Productivity

Human-Mimetic Handling: Optimizes work efficiency by replicating the precise dross loading and unloading motions of a human operator.

Autonomous Bin Management: Minimizes management touchpoints by automatically measuring dross accumulation and automating the discharge process.

Custom Tooling Design: Capability to design and manufacture optimized end-of-arm tools (EOAT) tailored to specific furnace conditions.

Minimized Failure Risk

Simulation-Based Validation: Conducts 3D simulations to perform interference checks and verify work performance before on-site installation.

Extreme Thermal Protection: Utilizes high-performance heat-resistant robots equipped with specialized thermal/fireproof jackets to minimize malfunctions and breakdown rates in molten metal environments.

Reliable Post-Management

Peace of Mind: Includes a 1-year comprehensive warranty for secure and reliable after-sales maintenance.

Implementation Results

ROI Period	18 months
Key Metrics	Workplace Improvement: Enhancement of the work environment through the complete unmanned operation of high-risk tasks. Quality Assurance: Improved aluminum production quality due to the consistent and continuous removal of byproducts (dross).
Client Feedback	By automating this high-risk task, we were able to reassign our workers to other areas, significantly improving the safety and overall work environment for our employees.