Initial situation
A 6-station casting carousel that has been in production for several years.
It is equipped with fixed single-mould die casting machines.
Automatic Casting and Unloading operations (carried out on 2 consecutive stations of the carousel).
Project perimeter
Needs expressed in the specifications
- Following a change in production, the castingprocess had to be modified to switch to tilted casting and add an automatic core setting operation.
- In order to respect the volumes to be produced, it will be necessary to load 3 moulds per die casting machine.
- Production with 1, 2 or 3 moulds on the same die casting machine
- The new parts require greater control over casting parameters, as well as a fairly long solidification time, which means that 4 stations on the carousel have to be dedicated to solidification.
- Core setting and part unloading operations carried out on the same carousel station
- Carousel must work with recipes system
Sofima proposal accepted by the customer
- Removal of the existing unloading cell
- Integration of 2 new core setting and part unloading cells
- Core supply via a 2-position table allowing the operator to load cores in masked time
- Hydraulic tilting die casting machines with proportional solenoid valve tilting control
- Replacement of die casting machines control cabinets with new ones to manage changeover and monitor process parameters
SOFIMA services
Mechanical studies
- Global layout (2D and 3D)
- Core supply table
- Robotic core setting cell
- Robotic part unloading cell
- Tilting die casting machines with 3 independent moulds
- Product / process interfaces (grippers, core fixtures, part fixtures)
- Workpiece output and engraving station
- All safety equipment (fences, interlocked door,...)
Automation and Robotics Studies
- Programming of unloading and core setting robots
- Integration into existing programme
- Modification of existing programme for production by recipe
- Die casting machines programming
- HMI Programming and Supervision - Industrie 4.0
- Programming Safety features in compliance with CE standards
Supply
- Fanuc anthropomorphic robots
- Core preparation table
- Core setting gripper for Fanuc robot
- Unloading gripper for Fanuc robot
- Parts output and marking station
- Electrical cabinets and enclosures
- Pneumatic panel and supply circuit
- Mechanical protection (wire mesh, automatic doors) and electrical protection
Installation
- Mechanical assembly
- Pneumatic hoses and connections
- Electrical wiring
Commissioning
- Input/Output test
- Robot commissioning (defining frames, checking trajectories, etc.)
- Blank tests
- 1st Pour
- Run at rate
- Up to speed
Factory 4.0
- Integration with existing plant supervision systems, creating over 500 accessible parameters
Documentation and CE declaration
- Printed and electronic User Manual in 2 languages (manufacturer and user)
- Paper and electronic Maintenance Manual in 2 languages (manufacturer and user)
- Assembly and sub-assembly drawings
- Spare parts list
- Complete parts list
- Pneumatic and hydraulic diagrams
- Electrical diagram of new cells and shells
- Updating the existing electrical diagram
