The massive shift from iron to aluminium and other light alloys – for both ecological and economical reasons – means foundries are investing heavily in new machinery. With the aluminium content in vehicles rising by 5.5 percent each year, some 12 million metric tons of aluminium will be cast in 2010. To handle this workload, around 70 new foundries will have to be built annually.

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ABB is moving right along with this trend, providing businesses with proven robot-based solutions including progressive production cell technology. ABB’s commitment to foundry automation is based on almost 40 years experience and covers every aspect of the production process – all the way from smelter to the finished automotive part. ABB’s robots provide efficiency along the entire value chain. This synergised-system concept based on specific robots designed for the need of each process offers many advantages, including enormous flexibility, high levels of reliability, and consistent capacity utilisation all along the foundry line.

All around the globe, ABB’s products and solutions are available from a unique distribution network that no other manufacturer can rival. Furthermore, ABB works with strong and competent partners, including the world’s leading OEMs and system integrators. The result: superior foundry process know-how, top-level software, hardware and services, providing customers with nothing less than the best possible solution. Anywhere, at any time.

ABB’s innovative IRC5 robot control system sets new standards with its modularised concept, a human-engineered FlexPendant programming unit with special foundry applications interface and fully synchronous, simultaneous control of up to four robots using MultiMove.

Cost-efficient offline programming is the best way to maximise return on investment in robotics. ABB’s simulation and offline programming software, RobotStudio, allows robot programming to be carried out in the office without shutting down production. It also enables robot programs to be prepared in advance, increasing overall productivity.

The elaborate programming required has been the biggest impediment to using robots to clean cast components, but ABB’s TeachSaver software package reduces this process by up to 90 percent. Even more, using a virtual offline robot cell ensures significantly greater accuracy than with classical teaching.

ABB’s performance service contracts include full service and total equipment management. Productivity improvement projects are routinely carried out, ranging from analysis and asset re-utilisation to system upgrades, modifications and refurbishing. Field service helpdesk and remote services are available 24 hours a day, 365 days a year. Parts and logistics services include spare parts sales, repair centres and inventory management. Finally, training for ABB products and systems as well as documentation are always included.

Foundry robots in the ABB family include:

IRB 940 Tricept: the robot for special jobs

• for pre-machining and material removal applications where accuracy is pivotal
• innovative mechanical design
• equipped with standard robot controller functionality

IRB 4450S: fast, compact and versatile

• A shelf robot optimised for working with medium-sized die-casting machines
• Ideal for foundry through its compact wrist and working range in downward direction

IRB 6650S: in a class of its own

• The largest work envelope in its class
• Ideal for die-casting machines in the 2000-5000 ton range
• Reaches exceptionally far and deep, can tilt completely backwards

IRB 1600: all-round athlete

• Backward-bending robot for small machines, 400-800 tons
• Faster than any robot in its class
• Payload options are 5 or 7 kg (up to 10 kg with “wrist down”

IRB 660: built for productivity

• 3.15 metre reach and 250 kilogram payload
• designed for upstream and downstream production, including handling of ingots and palletising.

For more information:

www.abb.com/robotics
ABB Automation Technologies
SE-721 68 Västerås, Sweden
Tel:  +46 21 34 40 00

 

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