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Effects of Using Robotics in Metalcasting

Automation of Foundry with RobotThe early development of robotics was driven primarily by the automotive industry. Their capabilities, and ease of use, were essentially limited by the state of computing and electronics. Developing alongside those dynamic technologies though, robots have enjoyed equally impressive growth in capability and cost ratio. But, in the modern world we understand too well the struggle to keep pace with technology. Technological advances in robotics and complementary technologies represent an extraordinary opportunity.

More than ever before, business leaders seek to maximize the value of their capital investments. Today's industrial robots, as well as the complementary technologies, offer features and capabilities that represent a historically unmatched "best buy" and an extraordinary new opportunity for metalcasters.

In consumer goods, we witness the daily tug-of-war between cost and the "state of the art" every day, and our efforts to stay at the technological forefront often seem futile. However, considering an industrial robot (a depreciable capital asset), investing in current technology is essential to achieving the maximum benefit of flexible automation.

Since industrial robots' debut in automotive diecasting in the early 1960s, their core characteristics - accuracy and precision, reach and payload capacity, speed, and power - have continuously improved. But, recent improvements in ruggedness and overall reliability make today's robots especially attractive to metalcasters. Moreover, integrated technologies for robot guidance, sensory feedback and user/programmer interface make the current robot offerings more versatile and more "intelligent" than ever. So effective are these technologies that in recent years there have been a number of partnerships established between robot manufacturers and sensor manufacturers in particular.

Robot guidance is not new, but machine vision manufacturers have advanced the quality, speed, resolution, durability, form factor and user-friendliness of their wares to such an extent that they have opened many new areas to robotic automation. Whether they use 2D, 3D, or 3D line-scan methodology, these products function as the robot's "eyes" caliper, and micrometer. They help to reduce or eliminate fixturing and hard-tooling, allowing greater flexibility (and perhaps the elusive single-piece flow.) Now, they can also act as real-time, 100% dimensional inspectors or map the surface of a casting to sense exactly where material should be removed in a finishing operation, helping to compensate for part variation.

Haptic perception (the capability of obtaining kinesthetic (force) and tactile information) plays a very important role in many operations

Integrated force sensing is perhaps the most compelling recent advance in sensory feedback for robots. Systems currently available allow robots to sense force and torque in all directions, for delicate tasks like component assembly, and for highly efficient material removal processes. They are particularly impressive at the pressure-critical task of grinding, and the latest force-control capabilities make it possible for the robot to maintain optimal normal force and feed force, and to react intelligently to the forces encountered. The robot can adjust its speed, alter its path or even change its sequence of operation altogether, based on the conditions it senses.

Robot integrators and solution developers bridge the gap between robot manufacturers and end users, driving much of the innovation and application diversity in the industry. Leveraging the technologies available from the world's leading robot manufacturers with the latest in peripheral equipment, such solution providers offer metalcasters unprecedented opportunities for process improvement, capability/capacity enhancement and cost reduction.

For more info visit:
Vulcan Engineering Co.,, or in Europe,
Foundry Management & Technology,
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