Case history: robotic automation cuts time in coreroom.Gebruder Gienanth-Eisenberg GmbH produces 400 coldbox sand cores per day for the production of high performance six- and eight-cylinder crankcases at its gray, ductile ductile /duc·tile/ (duk´til) susceptible of being drawn out without breaking. duc·tile adj. Easily molded or shaped. ductile susceptible of being drawn out without breaking. and compacted graphite iron shop in Eisenberg. Germany. As part of an ongoing improvement program, the company needed to increase production, reduce labor costs and improve quality of its core coating and handling. After an extensive evaluation, Gienanth focused on two core handling operations--clipping into the core wash and palletizing finished cores--for its initial automation efforts. These operations historically had been performed manually, and the biggest concern was to ensure robot handling would not stress, crack or otherwise damage the delicate sand cores. Two Kuka KR 500 heavy-duty robots were chosen for these operations, but before committing to the automation project, Gienanth commissioned a feasibility study "A Feasibility Study" is an episode of the original The Outer Limits television show. It first aired on 13 April, 1964, during the first season. It was remade in 1997 as part of the revived The Outer Limits series with a minor title change. to investigate possible methods for picking up the cores and see how the cores would respond to the robot motions. After the robots successfully completed a pilot run of motion patterns, speeds and accelerations, the robots were deployed in the metalcasting facility. The cores, which weigh up to 573 lbs. (260 kg) and mea sure up to 44 in. (113.5 cm) high, are moved on a conveyor Conveyor A horizontal, inclined, declined, or vertical machine for moving or transporting bulk materials, packages, or objects in a path predetermined by the design of the device and having points of loading and discharge fixed or selective. from the furnace to the rough orientation pickup station for the first robot. A photo electric sensor signals to the KR 500 when a sand core is present. The robot then registers the location of the core with a laser, determining its exact position in the pickup station. The robot picks up the core with its universal gripper and dips it into a bath of water wash to a defined depth. This protects the sand from the molten metal, preventing burn-in on the product. After clipping (1) Cutting off the outer edges or boundaries of a word, signal or image. In rendering an image, clipping removes any objects or portions thereof that are not visible on screen. See scissoring. See also WCA. the core into the bath, the KR 500 lifts it out again and transfers it to the apron apron, n a piece of clothing worn in front of the body for protection. apron band, n a labioincisal or gingival extension of an orthodontic band that aids in retention of the band and in proper positioning of the bracket. conveyor of the drying furnace. During this process, the robot carries out rotational motions Rotational motion The motion of a rigid body which takes place in such a way that all of its particles move in circles about an axis with a common angular velocity; also, the rotation of a particle about a fixed point in space. to allow the wash residues to drip off, thus preventing runs. Once on the conveyor, the sand cores pass through the drying oven and a cooling zone. They then are picked up by the second KR 500 and palletized for transfer within the plant. With the robotic system robotic system An integrated system of devices that automate production and manufacturing of goods and services Surgery An AI-based surgical assistant system, which processes sensory input from haptic interfaces and/or allows surgeons to act with more accuracy than fully implemented, Gienanth has reduced labor costs and shortened cycle times. Visit www.kuka.com for more information. |
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