February 2025 Volume 7

AUTOMATION

2. Moving Hot Product from Furnace to Forge and Through Forge Dies This application presents unique challenges due to the extreme heat and abrasive conditions. Automation addresses these chal lenges with specialized technology designed to complement the 6-axis robot's capabilities. These technologies include: • Heavy-Duty Conveyors: High-temperature chain conveyors for transporting glowing hot materials. • Heat-Resistant Grippers: Pneumatic grippers with heat shielding and water-cooling features for prolonged durability. • Temperature Sensors: Designed to monitor glowing red-hot parts for precise handling. While this process may not require cutting-edge technology, it is an intricate combination of materials science and robust engi neering. Companies like SCHUNK have set benchmarks in devel oping high-output grippers that can be adapted well for forging automation. 3. Automated Spraying of Forge Dies Spraying dies with lubricant is another step in the forging process where automation can be very effective. Although the technology is not highly advanced, fine-tuning the systems for optimal perfor mance ensures longevity and efficiency. Top components include: • Accurate dosing pumps to ensure proper lubrication mixture. • High-volume diaphragm pumps to facilitate fluid movement. • Atomizing valves and flow meters for precision spray patterns. • Pinch valves to prevent clogging when using high-solid content lubricants. CONDAT is a key player when it comes to automating die spray. Their CONDAMIX unit is an effective choice for both auto mated and semi-automated lubrication systems. Additionally, CONDAT has developed a range of lubricants specifically for the forging industry. Their lubricants support the forming of materials including steels and stainless steels, aluminum, bronze, brass or alloys of titanium, and nickel. 4. Moving Hot Product from Forge to Trim Efficiently transferring hot product from the forge press to the trim press requires a robust combination of equipment designed to • Servo-powered slides and chain conveyors for rapid transport. • Vision-guided systems capable of imaging glowing parts and guiding placement with precision. • Durable gripping systems mirroring those used in forge loading operations. Loading the trim press with a robot is quite straightforward, however the removal of flash after the trimming process can be a very challenging task due to the unpredictable nature of the process. Creative designs involving various equipment & tech withstand challenging conditions. Technological advancements include:

nology such as actuators, air cannons, machine vision and often die modifications, can be leveraged to tackle this challenge. This process highlights how clever engineering and innovation continue to refine traditional handling practices. 5. Inspection of Finished Products Inspection is critical in any forging operation, and advance ments in sensor technologies and software platforms are pushing the boundaries of quality control. Modern automated inspection ensures consistent product quality while significantly reducing inspection times. Innovations include: • 3D scanning for automated defect detection and detailed metrology. • Advanced cameras and sensors paired with AI algorithms for real-time analysis. • Software platforms that make this cutting-edge technology easy to use in production environments. Manufacturing Automation Systems (MAS) has developed an Intelligent Automation software package (QC Plus®) which enables advanced robotic 3D laser scanning for automating metrology, and inspection (rules-based and AI) solutions tailored for quality control, as well as adaptive tool pathing software features (Scan-To-Path™ Correction and Scan-To-Path™ Genera tion), which enable real-time robotic tool path adjustments to reduce scrap and automate rework. By leveraging automated inspection, plants gain tighter control over their production processes, improving both accuracy and reli ability.

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