Die Is Cast As South Yorkshire Manufacturer Opts For Robot-Based Automation

The cell was the brainchild of PMS Director Gordon Panter, who realised that a fully automated facility could bring significant productivity and cost benefits, particularly when applied to a new contract awarded by wire rope component manufacturer, Sheffield-based Gripple.

The robot cycle is short and relatively simple, with little scope at present for adding extra downstream tasks. The IRB 140 FoundryPlus robot picks up the casting assembly from the Frech diecasting machine using specially designed pneumatic grippers, and transfers it to a part separation station. A pneumatic press then separates individual castings from runner, and the robot directs the runner to a chute for reprocessing, before returning to the starting position for the next cycle.

Installed in the summer, the PMS investment appears to be completely justified, with the automated cell increasing manufacturing efficiency and reducing costs. Benefits include: total reliability in a harsh environment; release of skilled manpower; maximised space; improved quality and accuracy of castings; and a complete ‘closed loop’ for zinc waste.

Plans are in place for Geku to install an automatic feed for zinc ingots, so that a total ‘lights-out’ operation can be established.

Gordon Panter has previous experience in the plastic injection moulding industry, where automated production is commonplace, and when he decided to automate an ABB robot and Frech diecasting machine were the first items on his acquisition list.

‘The efficiency of our operation is achieved by eliminating variables, wherever possible. I felt that by buying the most efficient and reliable brands of robot and diecasting machine, a considerable number of variables would be totally eliminated,’ says Panter.

Having decided on an ABB robot, the IRB 140 FoundryPlus robot was specified after consultation with Nigel Richardson, Joint Managing Director of ABB preferred partner Geku.

The IRB140 robot is ideal for harsh environments and features full IP67-classified seals, which withstand pressure steam cleaning and liquid impacts up to 25 bar, even complete immersion in water for short periods. In addition, each robot is treated with tough, two-component epoxy coatings to prevent corrosion.

Richardson comments: ‘As well as operating in a relatively harsh environment, the cell needed to be both space saving and portable, so the IRB 140 FoundryPlus with its compact dimensions was ideal for the PMS operation.’

‘To achieve portability, we mounted the cell on castors - so it is highly transportable and can be moved away in seconds for access to the Frech for tool changes and servicing. Interfacing the DAW-20 diecasting machine to the IRB140 robot was also a relatively simple task, as Geku engineers have a wealth of experience with both Frech and ABB systems,’ he adds.

Commenting on the impact of the Geku/ABB automated cell on PMS Diecasting, Gordon Panter says: ‘We are a relatively small business and to be highly competitive we must also be highly efficient. This means that every square foot of workspace needs to be utilised and every employee 100 per cent effective. To these ends, the Geku-designed cell has had a most significant effect. It is very compact and highly efficient, scrap is reprocessed immediately - rather than allowed to build up in bulky skips - and an arduous, boring and labour intensive task has been fully automated, allowing our staff to use their skills on much more challenging and fulfilling operations.’

He adds: ‘The introduction of full ‘lights-out’ operation is the next milestone and a significant development for the future success of our business.’