Simple Solutions That Work! Issue 5

reduce waste (through reduced handling) and to increase quality. Newer automation is pushing die casting forward in a manner not thought of just a few years ago. Earlier adopters of automation already understand the benefits of automation and are expecting more as technology progresses. It’s not uncommon in the foundry industry to see either early adopt- ers of automation or their coun- terparts – known as laggards. Early adopters tend to explore new options and have played with newer methods whereas laggards are electing a ‘wait and see’ atti- tude, as they tend to fear financial implications and/or that jobs may be lost. The future of die casting is clearly only with companies that understand technology and the benefits of automation. ALUMINUM DIE CASTER This die caster is no stranger to smart technologies and knows how certain molds will be-have in their operation. They have a zero- fault strategy which means that each new mold is checked thor- oughly and with a spotting press. Mold spotting is a cornerstone in tool con-struction to achieve the highest precision with each die casting mold. This so-called fin- ish-ing touch ensures that the molds are flush, parallel, and tight. Any tinsel flash or slug, reduces the quality of the casting and reduces the service life of themold because it gets worn faster. CASE STUDY In the new die casting robotic cell, throttle bodies are produced. The tool was designed such way that four bodies are produced in one shot. This aluminumdiecaster often chang-es the products therefore, flexibility was a key requirement. Die casting cell requirements: • Processes – include all steps from casting to the punch trimmed part. • Capacity – 200,000 shots per year • Three-shift operation • Tool changes – must be simple and allow different articles and different batch siz-es depending on requirement. • Quality – from the cast to the output of the finished parts DIFFERENT MANUFACTURING PROCESSES– ONE PROVEN SEQUENCE Independent of the pre-cast product the sequence is as follows: • Thecentralpointintheautomated casting cell is a foundry robot with a two-jaw turning gripper picking the castings at the gate and transporting them without re-gripping, to all stations within the cell. • After removal from the casting machine the robot stops in front of a shot control equipped with IR sensors andevaluateswhether the castings are to remain in the mold. • For maximum flexibility of the cell the shot control module can be exchanged, de-pending on the cast product. • Very complex products are produced in the castingmachine with a three-plate-tool. 45 The complete product now is held by the robot into a quench tank to lower the temperature to an optimal range for further processing. After removal from the casting machine the robot stops in front of a shot control equipped with IR sensors.