Robotic finishing system improves capacity for engine head production.

A major supplier of diesel engines for a wide range of industries was recently challenged to improve engine component production at its metalcasting facility. Plant managers determined that automation was the best alternative to manual operations in order to meet the demand of increasingly higher volumes.

Foundry Solutions and Design LLC, Alpharetta, Ga., was contracted to assist with overall process specification development and plant modifications. The firm selected Fanuc Robotics America Inc., Rochester Hills, Mich., to design a flexible robotic system to handle the huge variety of parts through the various finishing processes, from initial shakeout to pack out for post processing. In addition, robots would handle the secondary processing of heads through stress relief furnaces.

The metalcasting facility produces parts in various sizes, from 0.5 cu. ft. (0.014 cu. m) at 150 lbs. (68 kg) to 5 cu. ft. (0.14 cu. m) at 670 lbs. (305 kg). The facility wanted a robotic system that would integrate new and existing equipment while minimizing manual labor and eliminating tool changeover between part styles.

Fanuc Robotics' Automation Systems Group divided the solution into three main areas: rough finish line, fine finish and heat treatment. The new system was able to provide solutions for a wide range of production challenges, including:

* handling six different part styles, the smallest parts handled two at a time;

* indentifying and verifying orientation and tracking parts through the various processes and machines;

* processing small parts at a rate of 240/hr. with the same equipment that handles large heads;

* locating rough castings and loading them onto machine fixture datum points to within 0.04-in. (1-mm) tolerance;

* developing a core hole opening and flash removal system to within 0.06 in. (1.5 mm) of parent material on irregular castings;

* enclosing processes to meet noise reduction targets;

* palletizing fine finished parts on existing skids for further post processing and inspection;

* identifying and depalletizing parts from manually-loaded skids to the roller conveyor of a continuous operation stress relief furnace;

* identifying and removing parts from the output side of the furnace.

In the end, the new automated system eliminated the need for manual changeover and adjustments of hard automation grinders for batch runs of individual part types at the metalcasting facility. Outsourced labor for chipping and grinding of castings was reduced, as were workers' compensation claims due to the elimination of areas of ergonomic concern. Handling and transporting activities of parts between processes was minimized, and the plant environment experienced improved air quality and noise reductions. Finally, the higher productivity rates reduced the overall part costs.

Select No. 002 at www, moderncasting.com/info