February 2021 Volume 3

AUTOMATION

it. Most foundries find initial success by working with an integrator and assigning an internal project champion for automation support. The integrator provides value with a thorough understanding of the nuances of automating the different processes, providing spare parts and technical support, and helping reduce the number of unknowns. In addition, working with an integrator that is certified by the Robotics Industry Association (RIA) ensures a safe and correct installation. The chosen supplier may also already have dedicated forging solutions, which significantly reduce the cost, lead time and in-plant skill set required to automate. For example, for most closed die applications a simple single axis sprayer offers fast and efficient spray application. Using PLC controls most operators and maintenance staff have familiarity with, multiple positions can be programmed to spray each position in the press in exact volumes. Since these machines have only a single driven axis, costs are much lower relative to six axis industrial robots with the trade-off being less flexibility.

control and data networks (SCADA) are essential to maximizing utilization and efficiency for years to come. By using the logic of mass customization, and some automation concepts adapted from the die casting industry, forgers can look to capture reshoring opportunities with additional capacity and control. Working with an integrator can provide quicker, easier to use solutions which lower the learning curve for automation. Your internal champion is critical for supporting the automation and maximizing utilization as the comfort with the new equipment builds and automation levels increase to tackle new and more difficult tasks. ■

Rob Ewing is a Product Manager for Rimrock ® Corporation, and holds a B.S. in Mechanical Engineering from The Ohio State University. Phone: 614-509-4177 Email: reewing@rimrockcorp.com

Working with the integrator, the internal champion provides the energy to tackle the new and different problem set now created with the new systems and tooling and can be critical to driving out initial fear and increasing uptime of the solution. In the best examples, this individual builds a knowledge base over time that enables a level of automation independence fromoutside integrators. Finally, successful automation goes hand-in-hand with ease of use. Operator interfaces and touch points of all equipment should be easy to understand and manipulate. In many instances, different languages are available to support an ever diversified workforce. HMI or robotic teach screens with pre-defined functions and buttons drastically reduce skill level to operate the system. While iPhone® level simplicity isn’t often achieved, it is reasonable to expect the automation interfaces to be intuitive and easily connected to the press equipment and plant networks. Cutting-edge networking devices such as EWON devices allow integrators or robot manufacturers private remote network access into the machines, which can be invaluable in troubleshooting, support and program changes. As the automation level increases in the plant, supervisory

Offering a complete line of automated spray equipment for forging applications that extend die life and increase throughput. In addition, Rimrock designs complete turnkey robotic systems for the forging market using ABB, FANUC or MOTOMAN .

sales@rimrockcorp.com www.rimrockcorp.com

+1.614.471.5926

Extend Capacity and Increase Quality with the F460 Sprayer

FIA MAGAZINE | FEBRUARY 2021 46