What is die-cast robotic machinery?
If you are looking for a way to increase the productivity on your production line, consider automating with industrial robots. Die casting machines can be used in a wide range of applications, so no matter your needs, there is surely a specific robot for you.
Revolutionizing Die Casting with Robotic Automation: A Comprehensive Overview
In the world of industrial manufacturing, die casting stands as a fundamental process, responsible for creating intricate metal components used across a multitude of industries. However, this method, essential as it is, presents its own set of challenges, particularly when it comes to efficiency, repeatability, and process reliability. Fortunately, the integration of robots into die casting processes has ushered in a new era of automation, revolutionizing how we approach this critical manufacturing method.
Let’s embark on a journey through the world of die casting with robotic automation, exploring how renowned manufacturers like KUKA, Fanuc, and Motoman have redefined die casting and foundry applications, enhancing productivity, quality, and overall efficiency.
Robots can automate the die cast process by quickly and efficiently pouring molten metal into a reusable mold. Die casting machines are used in a variety of industries and while material handling is a natural application, casting and foundry applications can be challenging.
KUKA Robots: Transforming Die Casting Cells
Revolutionizing Die Casting through Automation
Die casting processes often involve significant downtime during startup, maintenance, and development phases, leaving machinery underutilized. To address this challenge, Die Casting Technologies Center devised a groundbreaking solution that seamlessly integrates robots into the die casting workflow.
KUKA KR 125 Robots: The Pioneers of Transformation
Die casting Technologies Center devised a way around the problem of how starting up a series and development work can tie up machine capacity instead of allowing it availability for actual production. The company takes on outsourced tasks to get the die cast parts ready for production. Three KUKA KR 125 robots were used to transform an ordinary die casting cell into a fully automated manufacturing cell for a vehicle transmission. The KUKA KR 125 robots can remove parts, spray molds with a parting agent, and load thixocasting billets. They are mounted on top of the machine and spray the mold with a parting agent as soon as the controller releases the part.
Audi AG’s Die Casting Revolution with KUKA Robots
AUDI AG needed to invest in a die casting automated solution focused on process reliability, repeatability, short cycle times, and high flexibility. Again, KUKA robots came to the rescue. These requirements were filled by a six-axis Series 2000 KR 210 L150 F KUKA robot. The robot grips the casting by the sprue and removes it from the mobile half of the mold after the mold of the die casting machine opens. The ejectors in the mold eject the casting after the robot controller switches the linear unit to soft axis mode. The robot holds the casting up to an inspection station with sensors to check whether the part is complete. Defective parts are sprayed with a red dot. The robot then sprays and blow dries the halves of the mold.
Elevating Die Casting Automation to New Heights
Audi AG, a global leader in automotive manufacturing, recognized the need for a die casting automation solution that emphasized process reliability, repeatability, short cycle times, and flexibility. Once again, KUKA robots emerged as the ideal choice to meet these stringent requirements.
The Six-Axis Series 2000 KR 210 L150 F: Audi’s Robotic Companion
A six-axis Series 2000 KR 210 L150 F KUKA robot takes center stage in Audi AG’s die casting automation. This remarkable robot grips the casting by the sprue, swiftly removing it from the mobile half of the mold after the die casting machine opens. Ejectors in the mold then facilitate the casting ejection process under the robot’s precise control. The robot carefully carries the casting to an inspection station equipped with sensors to verify its completeness, marking defective parts with a red dot. Following inspection, the robot expertly sprays and blow-dries the mold halves, ensuring readiness for the next cycle.
Fanuc Robots: The Cornerstone of Die Cast and Foundry Automation
Unveiling Fanuc’s Versatile Die Cast and Foundry Robots
Fanuc, a trusted name in industrial robotics, has engineered robots tailored to diverse die casting applications. These robots play pivotal roles in critical tasks such as casting extraction, core assembly, die spray cooling and lubrication, dross skimming, and molten metal ladling.
Fanuc die cast and foundry robots are designed for a wide variety of applications, including casting extraction, core assembly, die spray cooling and lubrication, dross skimming, and molten metal ladling.
A Glimpse into Fanuc’s Die Cast Robotic Arsenal
A prime example is the Fanuc LR Mate 200iC/5L robot, a master of deburring aluminum die cast parts. Partnered with the “Deburring Machine” developed by YAC Robot Systems, this LR Mate employs an ATI pneumatic deburring spindle to expertly smooth die cast parts, ensuring impeccable quality.
Additionally, Fanuc R‑2000iS robots are instrumental in an automated die casting process for lawn and garden equipment, demonstrating their versatility across industries.
A Fanuc LR Mate 200iC/5L robot is used to deburr aluminum die cast parts in the “Deburring Machine” developed by YAC Robot Systems. The LR Mate uses an ATI pneumatic deburring spindle to smooth the die cast parts.
Fanuc R‑2000iS robots are used in part of an automated die casting process for lawn and garden equipment.
Motoman: Delivering Robust Die Casting Solutions
Motoman’s Contribution to Die Casting Automation
Motoman, renowned for its automation solutions, offers a range of die casting robots designed to thrive in demanding environments. Their die casting models often feature IP67-rated wrists, ensuring robust performance even in challenging conditions.
Exploring Motoman’s Die Cast Robot Lineup
Motoman’s die cast robot lineup includes the MH80, the MS80w(MH), the ES165D, the HP350D-200, and the HP600D, each tailored to different payloads and applications.
Motoman offers IP67-rated wrists on most of their die casting models. High gloss anti-corrosive paint aids in avoiding a sludge that sticks to a robot in a die casting environment. Some die cast robots Motoman offers include the MH80, the MS80w(MH), the ES165D, the HP350D-200, and the HP600D, with varying payloads.
Embracing Robotic Die Casting: A Smart Investment
Unlocking the Power of Die Casting Automation
As industries seek to optimize their die casting processes, the adoption of robotic automation emerges as a smart investment. Robots excel in enhancing efficiency, precision, and safety in die casting and foundry applications, making them invaluable assets.
Robots.com: Your Partner in Die Casting Automation
For those considering the integration of die casting robots, Robots.com offers a wide selection of both new and refurbished robots, including models from KUKA, Fanuc, Motoman, and more. Our expert team is ready to provide free price quotes and offer insights into how robotic automation can transform your die casting operations. Contact us online or call us at 877−762−6881 to embark on your journey toward revolutionizing die casting through automation.
Robots.com offers many of these robots for a discounted price. Whether you are looking into new or used die casting robots, contact us today for a free price quote online or to get more information call us at 877−762−6881.
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