Die Cast Robot Tending Automation

/, Robotic Integration/Die Cast Robot Tending Automation


The Challenge

Midwest Engineered Systems Inc. provided a die cast robot tending automation machine for a hardware manufacturer.

Midwest Engineered Systems Inc. was asked to provide the customer with a FANUC robot to tend a new Frech Die Cast Machine as well as load the cast part into a Trim Press. In addition, MWES has quoted additional automation and services to make a complete automation system.  The challenge of this project was to achieve an 18 second part to part cycle time.

The Solution

After a full evaluation of the project’s challenges and goals, Midwest Engineered Systems provided the customer with a complete solution, which included:

  • Fanuc Robot- This includes M710iC/50 with R-30iB Mate Controller, DCS Position & Speed Check, ASCII Program Loader, Soft Float, and PC Interface.
  • Robot Accessories- The equipment includes a robot EOAT with pneumatic gripper system, cable harness, and robot mounting base.
  • Part Verification Stand– This includes a stand and sensor array for part presence after the extraction process has been completed.
  • Dunk Quench System– The equipment includes a welded stainless steel tank, heat exchanger, HP Pump, all necessary controls for the system, all necessary valves, and all necessary piping and filtering.
  • Cooling Conveyor, Scrap Conveyor, and Chutes-   Integration of conveyors and chutes into the system.
  • Motorized Turntable– Integration of a turntable allowed parts to accumulate, meaning the Die-Cast and Robotic Part Extraction process to continue if the operator had step away for a few minute. The Turntable part accumulator was also a very efficient use of floor space.
  • Safety Features– This includes black mesh safety guarding, safety interlock door access, RAG stack light and emergency stop button. The safety solution supplied met the requirements set forth by ANSI/RIA R15.06-2012.
  • Controls System– electrical enclosure, electrical panel, power transformers for 480VAC – 120VAC, over current protection, contactors, Allen Bradley Compact Logix PLC w/Ethernet, Allen Bradley Panelview Plus Compact 1000 machine interface, electrical control interface for all system I/O, conveyor motor starters or drives, Wire way, terminal blocks, fusing, and safety system interface.


Impact to the Customer

The final Die Cast Robot Tending Automation provided the customer with the following benefits:

  • Higher Quality
  • More Efficient/Quicker part to part cycle time (18 seconds or less)/Higher Throughput
  • Improved Operator Safety
  • Improved Error Recovery
  • Improved Equipment Maintainability
  • Improved Scrap Recovery (MWES Scrap Recover System fed scrap directing back to the furnace)
  • Lights out operation improved overall system OEE
  • Improved floor space utilization

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