Process layout
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 |
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Workflow
| STEP 1. | Skimming: The robot scrapes and collects dross from the surface of the molten metal. |
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| 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. |
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.
Results
| Key Benefits | 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).
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| 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.
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