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.

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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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