Feature Article


SMART CASTING – Through Automated Casting Plant


by FEINGUSS BLANK


ndustry 4.0 is finding its way into foundries. Topics such as digitalization and automation are increasingly defining the daily work routine in many companies. The BLANK Group, therefore, started the development of an automated casting process as a future project several years ago. At the end of 2018, BLANK started automated casting. Over the past two years, this system has been further optimized. Today, two robots simultaneously handle the ceramic shell and the melt to help streamline the casting process. This approach is unique worldwide, reports Ralf Jedrysiak, Head of the Casting Production section at BLANK. “Our aim was to create relief for the employees in this physically


I 20 ❘ June 2020 ®


demanding work area. Also, the standardization of the processes enables repeatability that is reflected in the factors of quality and speed.” The newly created automated production cell is controlled in series production by only one production employee. First, this employee is responsible for preparing the shells that are preheated in a circular furnace inside the cell. This happens at the same time the melt is prepared for casting. After the liquid metal has been checked by the in-house metallurgical laboratory, the casting process can begin. The employee starts the process outside the casting cell by simply pressing a button. From this point forward, the robots work completely


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