Process layout
This is a machine tending automation solution that utilizes the ABB IRB 6700 Foundry Plus 2 to transport castings and automate the loading and unloading of workpieces.
The process involves transferring and handling molten metal at extremely high temperatures—a task that poses significant safety risks and results in slow production speeds when performed manually. By implementing ABB’s specialized foundry robot, the facility has successfully secured workplace safety and drastically increased production throughput.
Components
| Robot |
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Workflow
| STEP 1. | Ladling: The robot collects the molten metal. |
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| STEP 2. | Pouring: Injects the molten metal into the mold (casting). |
| STEP 3. | Dross Removal: Removes byproducts/impurities from the molten metal. |
| STEP 4. | Extraction: Picks up the finished casting from the mold. |
| STEP 5. | Discharge: Place the part onto the discharge conveyor for the next process. |
Features
Solution for Maximized Efficiency & Productivity
Optimized Cycle Times: Performs tasks at speeds perfectly synchronized with the casting production rate.
Dual-Machine Support: Leverages the robot’s wide reach and high payload capacity to manage continuous production across two casting machines simultaneously.
Improved Work Environment & Enhanced Safety
Hazardous Task Elimination: Prevents safety accidents by removing human workers from direct contact with high-heat molten metal and heavy castings.
Risk Mitigation: Automates high-risk handling processes to ensure a zero-accident workplace.
Superior Durability with Specialized Foundry Robotics
Engineered for Extremes: Utilizes a specialized foundry robot with high heat resistance and a superior IP rating for long-term reliability in harsh environments.
Foundry Plus 2 Protection: Designed to withstand the moisture, lubricants, and metallic dust prevalent in die-casting and foundry shops.
Results
| Key Benefits | Improved workplace environment through the unmanned operation of high-risk tasks.
Increased productivity due to significantly shortened cycle times.
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| Client Feedback | By automating high-risk operations, we have drastically improved the working environment for our employees while simultaneously boosting our overall productivity. |
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