May 2025 Volume 7

AUTOMATION

AUTOMATION ENHANCES SURFACE FINISHING IN THE FORGING INDUSTRY A Case Study in Bavaria By Michael Haas

T he forging industry is experiencing a transformation in surface finishing processes, driven by the increasing use of automation. This shift is prompting discussions about the evolving role of human labor, the relationship between traditional craftsmanship and new technologies, and how companies of all sizes can adapt to remain competitive. Automation in metalworking operations, including grinding, polishing and deburring, offers the potential to improve efficiency, precision and safety. Robotic systems can be programmed for precise motion and consistent control of parameters such as contact force and speed, resulting in more accurate and repeatable results. This can help improve product quality and reduce rework. In addition, automated systems can address challenges related to labor shortages and workplace safety. By performing physically demanding or repetitive tasks, robots can help reduce the risk of injury to human workers. Automation for All, Not Just the Giants While automation is sometimes perceived as being primarily for large-scale enterprises, it is also relevant to the competitiveness of small and medium-sized enterprises (SMEs). Successful integration of automation depends on factors such as selecting the right technology and ensuring smooth implementation. Case Study: rondolino Stoves The experience of Rondo Ringkachelofen GmbH, a stove manufacturer in southern Germany, illustrates the potential

impact of automation on a smaller company. The traditional family-owned company, which produces high-quality wood-burning stoves under the brand name "rondolino®," was struggling to keep up with increased demand due to the labor-intensive nature of manually grinding steel shells. Stephan Schneider, the company's CEO, noted the monotonous, tedious and time-consuming nature of the grinding process. This, combined with the increasing workload, led him to conclude that sooner or later the company would have to consider automating this part of the process. However, the decision to integrate automation into the traditional craft business was not an easy one. There were doubts and concerns that had to be overcome.

But Rondo decided to give it a try by partnering with FerRobotics. Grinding the steel shells is a delicate part of the process, requiring a great deal of skill on the part of the operator. Getting a robot to perform this process with the same level of sensitivity seemed to be the biggest problem for Schneider. Active Compliant Technology: The Key to Success After taking a close look at the existing processes and infrastructure, and after several test runs, Rondo was presented with a customized solution that eliminated all doubts and not only matched the surface quality of the manual process but far exceeded it. All FerRobotics tools are equipped with Active Compliant Technology (ACT), which gives the robots a sense of contact and enables precise force control in real time and in any situation. This makes it possible to perform material removal and finish tasks with breathtaking feed rates. A Rondo employee's summary: "The machine grinds four times faster, and the surface quality is impressive!" In fact, the automation eliminated manual grinding completely and accelerated the process by 75%. In addition, the automated approach resulted in a 30% savings in abrasive material, all of which led to a return on investment in less than 16 months.

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