Simple Solutions That Work! Issue 16

FLEXIBLE MANUFACTURING & ENGINEERING TRENDS 45 After all the finishing engineering is completed and the process plan is understood, the next step is to program the robot’s paths. Advances in robot technology allow this to be a relatively simple process for a trained technician. For instance, Fanuc and ABB robots are supplied with off- line programming software that allows approximately 90% of the movements to be programmed via the software. The final “fine-tuning” will be done in the cell with the casting. These movements are taught to the robot via joystick or pendants. Robot programming has historically scared many potential users away from robotic cells in favor of CNC. With the off-line programming suites available just about any maintenance or engineering technician can effectively program new castings for finishing in the cell. The right robotic finishing cell vendor will offer the foundry off-line programming as part of their continued service. Vendors provided off-line programming in concert with local foundry technical fine-tuning is a cost- effective process that introduces new castings to the finishing cell without having to contract on- site services. Other features to consider in a robot finishing cell include: • Sound-proof safety enclosure • Rotating table accepting any casting fixture and utilizing automatic clamping devices (for tool handled robots) • Quick change EOAT capability • Scrap handling and removal system • Thoughtful layout to accommodate cleaning • Flexible exhaust and debris collection hooding • Safety interlocked access door(s) • Remote teaching pendant or joystick Foundry’s considering automated cleaning or finishing cells we’ve prepared this brief comparison of robotic finishing cells vs traditional CNC cells. Robotic cells offer: • Increased accuracy and processing speed • Faster ROI • Several different castings can be loaded and processed per cycle • Greater flexibility for casting or tool handled processing • Almost unlimited casting capability and easy to add different tools • Increased tool life • Operator friendly loading onto fixtures • Off-line programming speeds set uptime and can be achieved without vendor technician’s • Flexible scrap handling and removal • Easier maintenance Modernizing any foundry must consider all processes and departments Hopefully this article helps to point out advantages of robotic finishing cells as an appropriate tool in any modernization effort while providing guidance for vendor identification and selection. Contact: SCOTT SHAVER s_shaver@emi-inc.com