August 2023 Volume 5

AUTOMATION

FoundryPro Robots Heavy-duty, FANUC FoundryPro robots are built for forging applications with better seals on robot joints, durable two-part epoxy paint, and stainless fasteners. All motors are covered to prevent overspray from sticking to the motor/encoder. To accommodate various billet sizes, custom end-of-arm tools are designed to work in conjunction with the robot. For forge loading robots, a two-jaw gripper provides the flexibility required to handle the variety of billet diameter ranges. Additionally, a parametric programming approach uses the user defined diameter and length to guide the robot to proper positions. New parts can be added by entering the diameter and length before and after the first hit. DCS zones prevent robots from crashing into obstructions, even if jogged manually by the Teach Pendant. End-of-Arm Tooling End-of-arm tooling is especially important in forging due to the environment and temperature of parts. Engineers will design the tool to survive hot parts by understanding the temperature, managing ambient condition, selecting quality components and materials, and applying cooling or lubrication when necessary. Efficient tooling design allows for easy change-over and simplistic repairs. Bin Picking Bin picking systems are designed to be easily customizable and capable of integrating into a wide variety of forging environments. With extensive vision engineering, forgers can automate the dangerous and mundane task of loading raw billets into induction furnaces. Vision sensors scan bins to determine location data for pickable billets before the end-of-arm tool is placed over a pickable billet by a robot. The robot raises the billet and presents it to a secondary camera that checks overall length before moving to the infeed placement zone. Unload/Load Solution Forgers often have to unload and load parts into furnaces and presses. While part orientation has to be maintained, parts also have to be quickly transferred from furnace to press. A large reach is required to cover all working points before parts are unloaded from the forge and placed on a transfer conveyor for downstream operations. Automation can also include part presentation via conveyance. Custom-designed end-of-arm tools carry a new part into the furnace to begin heating. The hot part is picked out of the furnace and placed into the forge die. After the forge press cycles, the unload robot removes the part as the die spray robot coats the dies prior to To prevent parts from sticking on dies, a lubricant is sprayed on the die surfaces – or “die spray.” This is often a graphite and water combination – the water is used to cool the die steel and carry the graphite. Automating this process can allow for consistent and repeatable results which yields better quality and longer die life. the next cycle. Die Spraying

Billet Feed To transfer and load hot parts, conveyance can be implemented. These conveyors are also used to sort billets that are under/over the desired temperature. Sorting happens via air-operated diverters that send cold billets to a salvage bin and over-temperature billets that cannot be re-used to a separate bin. These conveyors can be equipped with quick-change, adjustable side rails to accommodate diameter changes. Controls & Software To further optimize forging shops that have already begun to automate, production can be increased by adding additional robots with new, scalable designs. By using a PLC as a traffic manager, robots and peripheral equipment can work in harmony with the forging equipment. FANUC offers Intelligent Interference Check (IIC) Software, which when implemented properly, prevents robots from crashing into each other or producing a deadlock situation. An experienced integrator will also equip robots with Move Safe programs, allowing them to move from any position along their normal paths to the home/safe position without colliding into any obstructions. Automation Plan – Questions to Consider It is essential for integrators and forgers to develop an implementation plan. This plan includes installation of equipment, day-to-day roles and responsibilities, shift support, and start up. Maintenance and support also need to be discussed. Lubricants need to be changed and batteries need to be replaced. With the aid of an experienced integration partner, forgers can develop a maintenance plan to prevent downtime due to repairs. Who will maintain the equipment? If a robot is integrated, operators have to be trained in programming and operation. This will help forgers internally support daily robot operation and basic troubleshooting. Who is the robot champion on each shift? A lot of forge shops are facing a serious lack of labor. To alleviate labor shortage, consider automation with smaller projects to get the facility accustomed to integration. Take the time to train employees as they begin to work with robots to optimize their day to-day responsibilities. After a successful first integration, work with an integrator to standardize robots, tooling, and controls for future automation. An experienced integration partner will help forgers identify potential automation solutions that their customer is comfortable with integrating, building an everlasting synergy to continuously optimize processes and increase production. Shayna Nenni Marketing Manager Adaptec Solutions Phone: 800-724-5794 Email: shayna.nenni@adaptecsolutions.com

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