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product quality, reproducibility, flexibility in production, quantity and cycling. “So far, the undefined formation of cast burrs has made a


robot-based automation in post-processing more difficult or partially even impossible at Heidenreich & Harbeck,” André Peters said. With the solution found now, the company has successfully mastered this challenge. Te KUKA foundry robot mounted on a console at Heidenreich & Harbeck is equipped with a number of processing units for cleaning/ polishing the cast burrs. Once the burr is determined accu- rately, the robot starts with the precise post-processing with great reproducibility. Te robotics experts at Boll Automation were able to


overcome the obstacle of the indefinability of the cast parts thanks to upstream testing technology, and thus enable a targeted post-processing. Te KUKA KR 120 R2900 F extra robot used for this purpose is not only equipped with a change system for receiving processing tools but also with a sensor system detecting the exact position of the different burr contours. Te six-axis robot belongs to the KUKA KR QUANTEC series and is used as foundry version. KUKA KR QUANTEC robots are particularly compact and enable space-saving cell concepts. Furthermore, the 29 basic robot types of the series are characterized by their bandwidth of load carrying capacities ranging from 90 to 300 kg, their range of 2,500 to 3,900 mm and their long maintenance intervals of up to 20,000 operating hours. All models are mounted on a compact base frame with almost identical drilling pattern for anchoring. Te foundry version has some additional benefits, which


have been specifically developed for foundries: Tanks to the use of special painting, a heat-, corrosion-, lye- and acid- resistant surface protects the robot, just like special gaskets at the motor and gearbox flanges. Te foundry wrists holding the gripper tools, which are made of heat-resistant special steel, are painted with a specific aluminum white paint, which allows an even greater heat-resistance in this particu- larly critical area. For use in extremely rough environments, it is furthermore important that the electronic system in the robot is permanently secured against dust and dirt. Atmo- spheric overpressure in the enclosure has proven particularly effective in this regard. “Due to the combination of robot and three-axle po-


sitioning unit with a load carrying capacity of 750 kg, the system achieves the highest degree of flexibility possible as it is able to deburr different cast parts from all sides,” said Kai Helmstetter, technical manager of Boll Automation. He added that this increases the cycle times in post-pro- cessing in confined spaces dramatically. Other benefits of the new automation solution: Te individual robot-steered post-processing is optimized for the respective workpiece. Tus, the quality can be improved and kept at a constantly high level, the tools are spared and a great level of repro- ducibility is given despite the different manifestations of burrs. Last but not least, Heidenreich & Harbeck were able to make the workspaces more humane thanks to the new automation solution. 


理,或者面临极重、灰尘过多、湿度很大的工作环 境,或后处理中产生飞屑,因此,环境对人和机器都 产生了压力并且要求最大的强度。除此以外,还经常 有产品质量、可重复性、生产灵活性,产量和生产周 期等方面的高要求。


“目前,不明原因产生的铸件毛刺使后处理中的以机 器人为主的自动化处理更加困难,甚至一定程度上可能 在Heidenreich & Harbeck公司难以进行,”安德烈• 彼得斯说。就目前的解决方案而言,公司已成功突破了 这一挑战。在Heidenreich & Harbeck公司控制台上安 装的库卡铸造机器人,装配了很多清理/抛光毛刺的工 艺装置。毛刺准确定位以后,机器人就以最大的可重复 性开始了精确的后处理工作。


利用逆行向上的检测技术,波尔自动化公司的机器 人能够克服铸件毛刺不确定性的障碍,从而,可以进行 有针对性的后处理。为此,库卡公司的KR 120 R2900 F机器人不仅装配了用于接收处理工具的子系统,还有 检测不同毛刺具体位置的感应系统。该六轴机器人属 于KUKA KR QUANTEC系列,用于铸造行业。KUKA KR QUANTEC机器人特别紧凑,实现了节约空间的铸 造单元理念。此外,该系列的29个基本机器人类型的 特点是其负载范围可以从90-300kg,宽度从2,500- 3,900mm,他们的长期维护周期可达20,000个运行小 时。所有型号的产品都安装在紧凑的基础框架上,几乎 具有相同的固定装配孔。


铸造机器人还有一些特别为铸造厂研发的其他用途。 由于使用了特殊的涂料,使耐热、耐腐蚀、耐碱液和耐 酸的表面可以保护机器人,就像发动机和变速箱凸缘的 特殊垫片的作用一样。铸造臂紧握使用耐热特种钢制成 的钳子,并且喷涂有特殊的铝白色漆,使其在关键区域 的耐热性更好。机器人的电控系统可以永久地防止灰 尘,因此,能在极端恶劣的环境中使用显得更加重要。 附近的大气超压已证明在此情况下是特别有效的。 “结合机器人和负荷能力为750kg的三轴定位单元, 该系统达到了最高的灵活性,因此,它能够从各个角 度去除毛刺,”波尔自动化公司的技术经理Kai Helm- stetter说。他还补充说,这将明显地增加有限空间内 后处理的循环次数。新的自动化解决方案的其它好处: 由机器人操控的后处理单元可以分别对铸件进行优化。 因此,尽管毛刺有不同的表现形式,产品质量可以得到 提高并稳定保持在较高的水平,还节约了设备的使用, 保证了较高水平的可复制性。最后一点但并非不重要的 是,由于采用了新的自动化解决方案,Heidenreich & Harbeck公司能够使工作环境变得更加人性化。 


78 | FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION June 2015


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