Simple Solutions That Work! Issue 14

Continued on next page 31 ROB EWING Product Manager Lincoln Electric Automation, Columbus ARTICLE TAKEAWAYS: • 3 methods of automating the ladle process in die casting • Benefits of the 7AA arm I n today’s foundry, any die caster can benefit from higher quality metal and increased throughput. This is especially true as customer requirements become more demanding. Figure 1: Example 7AA on Fanuc Robot IMPROVE CASTING QUALITY WITH PRECISION 7TH AXIS LADLING In die casting, there are well over 300 variables that impact part quality, and relying on trusted suppliers to provide the right equipment enables a producer to better control those variables. With better process control comes the high-quality results customers’ demand. Those same suppliers must also be able to provide a solution that is easy to install, optimize and maintain to maximize the return on investment. Automating the ladle process from a holding furnace to the shot sleeve is one of the easiest and fastest returns on investments a die caster can make in their facility. There are three generally accepted methods of automating the ladle process in die casting: fixed path or linkage style robot, industrial six-axis robot with a fixed cup mounted to the robot flange, and a six-axis robot with an additionally driven 7th axis arm (7AA) extension. Most are familiar with the first two methods of ladling, however as a recent advancement, the benefits of the 7AA arm are not as well understood. A properly designed and setup arm enables: 1. Reduced setup time 2. Increased opportunities for optimization 3. Increased accuracy and part consistency 4. Increased uptime and OEE 5. Cleaner metal The defining feature of the 7AA is the additional servo motor to drive the ladle cup. The servo is integrated with the robot controller through an additional drive in the robot cabinet. A support structure that extends the cup out a given length from the robot flange gives the tool added flexibility. The drive mechanisms of the arms are typically direct shaft drive or chain and sprocket. There are trade-offs to each drive design, and a supplier should be able to guide you to a solution that works best for your application and maintenance staff. Like any piece of equipment, a 7AA that cannot be maintained correctly will yield inconsistent parts. ADVANCED MANUFACTURING SOLUTIONS