Gantry robot improves productivity of die casting process

Citation

(1999), "Gantry robot improves productivity of die casting process", Industrial Robot, Vol. 26 No. 3. https://doi.org/10.1108/ir.1999.04926caf.002

Gantry robot improves productivity of die casting process

Keywords Die casting, Robots

ABB Flexible Automation of Milton Keynes has supplied additional robot installations to VAW Motorcast of Leeds as part of a recent investment in new facilities for the production of aluminum heads for Land Rover's new five cylinder turbo-diesel engine.

The VAW Group is the world's largest independent supplier of aluminum engine blocks and cylinder heads. ABB robots were first installed in 1995 at the company's new foundry in Cross Green. They are performing a variety of handling tasks including the pouring of molten metal. The success of these robots has led to further investment at VAW's original premises in Clarence Road.

The new installations comprise a de-flashing cell based on a conventional six-axis IRB 4400 robot and a large area gantry robot system, both of which were installed by ABB Flexible Automation as complete automation systems.

"The main benefit of a turnkey arrangement is being able to deal with a single contractor prepared to take responsibility for delivering a viable operational solution," explains VAW facilities manager Mark Hailwood.

"The specification and procurement of foundry automation raises many issues concerning the integration of equipment from different vendors. Whilst we have learnt a great deal about automation from our Cross Green installations, we decided to minimise the risks by involving ABB Flexible Automation early in the planning process.

'"ABB's experience backed up by the appointment of Project Managers by both VAW and ABB has resulted in a smooth installation. We are now fine tuning the process to achieve optimum productivity," he said.

The gantry installation straddles a number of gravity die casting machines. Its specially designed gripper tooling and reliable computer control places the sand cores into the dies ­ a very delicate operation requiring precision positioning (see Plate 2).

Plate 2 In operation the gantry robot picks up the sand cores from a loading conveyor and places them into the die cavities of each of the machines. It then returns to collect the finished casting, removes the feeder gate and delivers it to the take out position

The main drivers for increasing automation were the need to control quality and ensure consistency in the process. The automation has also increased overall productivity by using manpower more efficiently and allowing additional operations, such as automatic cropping of the feeder, to be incorporated into the same line.

The speed of the process has not changed since this is governed by the time taken for the casting to solidify. Once programmed however, robots will perform the same task tirelessly, enabling production to run continuously 24 hours a day, six days a week.

The de-flashing cell is another example of a robot taking over a repetitive task that requires manual dexterity and is tiresome for human operators. Fettling by hand can involve the use of small hand tools that are difficult to operate and require operators to wear protective equipment.

Equipped with a double-headed router tool, the robot completes the machining cycle in less than three minutes. The only precautions taken by VAW operators to ensure consistent quality is to keep the cell enclosure clean by removing swarf regularly with an industrial vacuum cleaner.

For further information contact: Jane Attwood, ABB Flexible Automation Limited Auriga House, Precedent Drive, Rooksley, Milton Keynes MK13 8PQ, UK. Tel: +44 (0)1908 350300; Fax: +44 (0)1908 350301.