February 2025 Volume 7

AUTOMATION

UNLOCKING EFFICIENCY IN THE FORGING LINE WITH FORGING AUTOMATION TECHNOLOGY By Mario Trizzino T he advent of automation has brought transformative changes across industries, and forging is no exception. By integrating advanced technology, forging plants are not only offsetting cumbersome manual labor but are also significantly boosting produc tivity, improving efficiency, and achieving superior quality control. At the heart of these advancements lies a key enabler of auto mation—the 6-axis robot. This article explores how automation, championed by robotic technology like the FANUC Foundry Pro series, is revolutionizing tradi tional forging operations. We’ll examine five key applications where automation is making a significant impact, from loading raw mate rials to the final product inspection.

• Two-part epoxy paint that is more durable than standard paint. • Double seals on all axes. • Stainless hardware on all non-load bearing bolts. • Motor covers. • Precision control for complex, repeatable tasks in forging operations. The 6-axis robot serves as the backbone for a variety of applica tions, and with its capabilities, forging plants have begun to tackle tasks that were once reliant on manual labor. Here are five core applications where automation is driving change: 1. Loading Raw Product into the Furnace Loading raw materials used to be a manual, labor-intensive task prone to injuries. However, advancements such as 3D robotic bin picking technology have transformed this process. Robotic bin picking allows robots to intelligently locate and pick parts from bins, increasing flexibility and efficiency. These systems are equipped with advanced vision system, including cameras and 3D sensors to help the robot understand and perceive the location/orientation of parts in the bin. Coupled with magnetic gripping technology, the robot can dynamically pick steel billets in almost any configuration. Recent developments of end-of-arm magnetic tooling include variable field output grip pers that enable optimal part handling of varied weights and sizes. Our solutions have found success with Magswitch as they offer advanced magnetic gripping solutions designed for ferrous metals with a high mix of billet diameters and lengths. By automating furnace loading, plants have achieved better throughput with fewer errors, saving both time and effort. Addi tionally, injuries from pinched fingers have been drastically reduced.

The Role of the Six-Axis Robot in Forging Automation When it comes to automating the forging line, the 6-axis robot stands out as the central piece of equipment enabling seamless integration with other advanced technologies. Specifically, the FANUC Foundry Pro series is a preferred choice for integra tors like Adaptec due to its robust design tailored for the extreme conditions of forging plants. With its ability to withstand high temperatures, handle heavy payloads, and adapt to diverse appli cations, this robot is a game-changer for automating critical processes. Key features of the FANUC Foundry Pro series include: • Wide range of model sizes to support various payload capaci ties and applications. • Designed to withstand durability in high-heat, abrasive envi ronments.

FIA MAGAZINE | FEBRUARY 2025 37