Simple Solutions That Work! Issue 5

• The double gripper prevents damageand safely removes parts from the die casting machine. • Once the part has passed inspection, the spray system begins to spray par t ing compound into the open mold and thus prepare the next shot. • The complete product now is held by the robot into a quench tank to lower the tem-perature to an optimal range for further processing. EXCELLENT TRIMMING WITH ONLY ONE CUT For execution of the next process step the robot inserts the casting into the trim tool which is situated in the three-column punching trim press SEP13-60. The press sepa- rates the four components and removes all casting flashes in one single work stroke. The die casting press includes mechanical features like bigger clamping surface, easier access for maintenance purposes and clearly improved energy efficiency, among others due to the use of servo-mo- tor basedpumpdriveswhich allows further reduction of cycle times ROBOT IS ABLE TO REACT TO CONDITIONS The robot as the most intelligent system in the cell reacts to exter- nal events and, for in-stance, to save energy switches off the trim press if it is not needed in the pro- duction pro-cess at the moment. Doing so, the robot considers the system-specific wakeup-phase and starts the press drives in due time in order not to delay the pro- duction. A new intuitive oper-ator concept was incorporated in the control Dialog IV. After the punching process the scraps fall through openings in the press table into a recy-cling con- tainer the contents of which will be remelted again later. The punched components remain in the upper die after opening of the press. A sliding table enters from the side onto which the castings are now ejected by an ejector. By a tilting movement the finished parts now get to the “O.K”. chute. To improve reaction to special requirements, it is additionally possible to feed out the “O.K”. parts prior to trim- ming via a second chute to insert themmanually into the press later, if necessary. In meetings with system suppli- ers the interfaces and logs were defined, so that all sensor values can be evaluated and each device communicates with the robot control. The robotic work cells replaced old cells that has been in use for decades. While they were still producing high quality parts with great service; newer technolo- gies greatly enhanced the produc- tion with more processes being managed by the robotic cell to fully deploy the “one piece flow’ Lean Manufacturing Principle, to reduce waste and increase results. Contact: Christopher Clark [email protected] 46 Technical data of the casting cell - Die casting machine Frech DAK 720, mold clamping force 800t, shot weight cur-rently 3,5 kg - Spray system fromWollin - KUKA robot KR30-3 in foundry design with turning gripper - Control: KR C4 - Standardized interface to the die casting machine DISPO 15 with premature spray release directly after parts removal - Reis 3-column punching trim press SEP 13-60 with parts re- moval unit - Parts’ control - Reis quench tank - Parts chute - Perimeter guarding according to applicable standards The press separates the four components and removes all casting flashes in one single work stroke.