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Robot in Foundry

ABB is a major supplier of automation equipment to foundries, with revenues of $1.6 billion in 1998. It has over 30 years of experience in foundry automation and installed over 6,000 robots in foundries by 1999. ABB focuses on automation solutions for aluminum casting, particularly for automotive applications, with growing demand driven by goals to reduce vehicle weight and fuel consumption through increased use of aluminum.

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0% found this document useful (0 votes)
359 views29 pages

Robot in Foundry

ABB is a major supplier of automation equipment to foundries, with revenues of $1.6 billion in 1998. It has over 30 years of experience in foundry automation and installed over 6,000 robots in foundries by 1999. ABB focuses on automation solutions for aluminum casting, particularly for automotive applications, with growing demand driven by goals to reduce vehicle weight and fuel consumption through increased use of aluminum.

Uploaded by

thiru71082
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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ABB Flexible Automation

OH Foundry 2000 9910-1


ABB in Foundry Automation

Key data 1998


• ABB Group
- Revenues: USD 35 billion
• ABB Flexible Automation
- Revenues: USD 1.6 billion
• Foundry Automation
Main focus downstream aluminium
From cast-houses to finished parts
- Revenues: USD 70 million
- 750 robots a year

ABB Flexible Automation


OH Foundry 2000 9910-2
Thirty Years in Foundry Automation

• First robot to an ABB foundry


already 1969
• 25 robots in operation in ABB´s
foundries by 1972
• 6,000 ABB robots installed in
foundries 1999
- 3500 High Pressure Die Casting
- 1500 Gravity Die Casting
- 1000 Sand Casting

ABB Flexible Automation


OH Foundry 2000 9910-3
ABB Foundry Business

Number of robots

300 425 500 675 750

1994 1995 1996 1997 1998

ABB Flexible Automation


OH Foundry 2000 9910-4
Growing Aluminium in Automotive

Driving forces
• Lower fuel consumption
• Workable recycling
• Lower aluminium price

Indicators
• Global change from iron/steel to aluminium
• 50 new large plants per year
• 50-100 major foundry expansions
per year
• Robotized automation of foundries
established

ABB Flexible Automation


OH Foundry 2000 9910-5
Rapid Increase in Aluminium Castings

Yearly growth 300 000 tons


Million tons

10

1991 1996 1999 2013

ABB Flexible Automation


OH Foundry 2000 9910-6
Focused Casting Processes

Casting Lines
High Pressure Die Casting Gravity and Low Pressure
Die Casting

ABB Flexible Automation


OH Foundry 2000 9910-7
Focused Automotive Parts

• Cylinder Heads
• Engine Blocks
• Engine Parts
• Transmission Parts
• Subframes
• Security Parts
• Aluminium Wheels
• Body Parts
• Aluminium Ingots

ABB Flexible Automation


OH Foundry 2000 9910-8
Automotive Captive Customers

ABB Flexible Automation


OH Foundry 2000 9910-9
Automotive Subsupply Customers

• A-CMI, Norway • Meridian, Canada


• Ahresty, Japan • Montupet, France
• Alcoa, USA • Mössner, Germany
• Alusaf, South Africa • Reynolds, Canada, USA
• Enkei, Japan • Ryobi, Japan, USA
• Fuchs, Germany • Superior, USA
• Honsel, Germany • VAW, Germany, UK
• J L French, USA, UK

ABB Flexible Automation


OH Foundry 2000 9910-10
Comprehensive Foundry Robot Program

• IRB 140 Foundry


• IRB 2400 Foundry
• IRB 4400 Foundry
• IRB 4400 Shelf Foundry
• IRB 6400 R Foundry
• IRB 6400 Shelf Foundry
• Controller Foundry
• Track Motion Foundry
• Cleaning tools

ABB Flexible Automation


OH Foundry 2000 9910-11
Foundry Product Adaptions

• High tightness
• Special coating
• Resistant to aluminium spits and
flashes
• Heat resistant
• Steam washable
• Water cooled
controller
• Foundry adapted software,
FoundryWare

ABB Flexible Automation


OH Foundry 2000 9910-12
FoundryWare

• ExtractWare High Pressure Die Casting


• SprayWare High Pressure Die Casting
• FlashWare High Pressure Die Casting,
Gravity Die Casting
Sand Casting
• CastWare Gravity Die Casting

ABB Flexible Automation


OH Foundry 2000 9910-13
Foundry Market Approach

Products and Systems


provided by ABB
• High Pressure Die Casting
• Gravity Die Casting

Systems with ABB robots provided


by Partners
• High Pressure Die Casting
• Gravity Die Casting
• Sand Casting
• Brass Casting

ABB Flexible Automation


OH Foundry 2000 9910-14
ABB Foundry Application Centers

Die Casting
• Germany
RobExtract,
RoboSpray and RobInsert

• Switzerland
RoboFlash

• Sweden
RoboJet

• USA, Rimrock
RobExtract,
RoboSpray, RoboFlash

ABB Flexible Automation


OH Foundry 2000 9910-15
Application Packages for
High Pressure Die Casting

Large Die Casting Machines RoboFlash

RobExtract

RoboSpray

RoboJet

RobInsert

ABB Flexible Automation


OH Foundry 2000 9910-16
Application Packages for
High Pressure Die Casting

Small and Medium Sized Die Casting Machines

RoboSpray RoboFlash

RobExtract

ABB Flexible Automation


OH Foundry 2000 9910-17
Application Package for
Aluminium Casting

Casting

RoboCast

ABB Flexible Automation


OH Foundry 2000 9910-18
Application Packages for
High Pressure Die Casting

Skimming Stacking

RoboSkim RoboStack

ABB Flexible Automation


OH Foundry 2000 9910-19
ABB Partners

• Acheson • Idrapresse • Pomac


• Buehler • Italpresse • Prince
• Bula • Kurtz • Remetal
• GF DISA • KWC • Rimrock
• Ellison • Laempe • Toshiba
• Fata • Loramendi • Vulcan
• Fill • Mapos • Weco
• Frech • Mecana • Wollin
• Gautshi • Mueller • Yxlon
• Hottinger Weingarten • UBE
• Mössner

ABB Flexible Automation


OH Foundry 2000 9910-20
Application Packages
Supplied by Partners

RoboShell

Rob X-ray

RoboFoam

RoboGrind

ABB Flexible Automation


OH Foundry 2000 9910-21
Honsel, Germany

• Die Casting Machine GDK 2000


from Müller-Weingarten, Germany
• Four-cylinder in-line engine block
and transmission housings
• Workpiece weight 20-30 kg
(engine blocks)
• ABB robots on track motion
• Feed, insert, unload (RobInsert,
RobExtract), spraying, sawing and
handling devices

ABB Flexible Automation


OH Foundry 2000 9910-22
GM Brazil, São Paulo

• Transmission House Castings


• 3 Die Casting Machines from
Bühler
• 12 ABB robots
- 5 IRB 6400
- 4 IRB 4400
- 3 RoboSpray
• Requested output: 1480 deburred
castings in 40 hours

ABB Flexible Automation


OH Foundry 2000 9910-23
VAW, Cross Green, UK

• Aluminium Cylinder Heads


• Land Rover five-cylinder turbo-
diesel engine
• 19 ABB robots at the VAW Group
• First installed 1995
• Casting
• Handling
• Deflashing

ABB Flexible Automation


OH Foundry 2000 9910-24
A-CMI, Lista, Norway

• Strategic alliance between Alcoa


Aluminium and CMI-international
• Aluminium subframes for Volvo
S80 and V70 Cross Country
• Production time for one subframe,
6 minutes (capacity 1 subframe
per minute)
• 35 ABB robots
• Sand core handling, core knock-
out finishing, dimension control,
deburring waterjet cutting, x-ray
and shot blast unloading

ABB Flexible Automation


OH Foundry 2000 9910-25
Ford WAP, Windsor, Canada

• Castings for Ford engines


• 1 million cylinder blocks and heads
per year
• 94 IRB 6000 robots for assembly of
the moulds
• 9 IRB 8000 gantry robots for
handling of the fully assembled
moulds and castings

ABB Flexible Automation


OH Foundry 2000 9910-26
First Automotive Works / Daewoo,
Yangtai Peninsula, China

• Joint venture between Chinese


FAW and South Korean Daewoo
Group
• 1.4 l and 1.6 l GM engines
• Four Cold Box Core Shooting
Machines from Hottinger
• 3 ABB robots built for complete
core handling
• Capacity: 300 000 engine blocks
per year

ABB Flexible Automation


OH Foundry 2000 9910-27
Hillside Aluminium Smelter,
Richards Bay, South Africa

• Aluminium Ingot Production


• Largest robot installation in South
African Foundry Industry
• 15 ABB robots
• Dross-Skimming
• Stacking
• Bundle-Truck Loading

ABB Flexible Automation


OH Foundry 2000 9910-28
Benefits of Foundry Automation

• High quality and reduced scrap


rates
• Higher machine utilization and
higher up-time
• Increased manufacturing flexibility
and shorter set-up times
• Higher productivity and lower
manufacturing cost per part
• Improved working environment
• Labour cost reduction

ABB Flexible Automation


OH Foundry 2000 9910-29

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