All the technological solutions developed by Tiesse Robot in the foundry sector, and which are presented at the 2015 international trade-fair, are based on the use of Kawasaki robots with a capacity of 3 - 700 Kg in various series - in particular the RS 3-80 kg series, the ZX 130-300 kg series, the MX 350-700 kg series and the CX 110-210 kg series.
New CX range with 110 to 210 kg capacity sizes. The new CX robot range is presented in 110, 165 and 210 kg capacity sizes. These robots have highly-appreciable speed and space saving characteristics that make them a new robot handling market benchmark.
The new machines have been optimized for all handling, casting deburring and machine tool interlocking operations, etc. Another major feature is how easy they make it to outfit robots of the cable ducting, solenoid valve positioning type, etc. They can also be combined with the new type of compact universal controller E03, designed to dialogue with the software of the entire Kawasaki robot range with a class 4PL safety standard.
Among its best-selling products, Tiesse Robot also offers the BX200 hollow wrist spot welding robot, dedicated principally to the Automotive industry.
Kawasaki Robot BX200 for Handling and Spot Welding operations. The BX200L robot features a hollow wrist with a 63 mm through hole for the operating cables of the servo gripper motor and the power cables for the transformer of the servo gripper and which enables the robots to operate side by side without the cables and suspended connections outside the machine interfering with one another at all. The use of special motor drives and connection with the latest generation of Type E Controllers, with a special routine for calculating accelerations and decelerations, has made it possible to reduce work cycles by around 15/20%, while the base design requires about 50% less floor space than the ZX model, which in any case remains in production for quick handling applications.
The degree of protection of the wrist remains IP67; the total weight of the robot is instead about 70% less than the equivalent ZX model. The two work areas provided make it possible to insert these robots into any type of production system.
Let us now take a look at the example (see photo) which represents the interlocking of a gravity casting process using a KZX300 Robot, able to cast 50 kg of aluminium and featuring an automatic tool change that enables the robot, once casting has been completed, to release the casting arm and pick up a gripper for the automatic unloading of the solidified casting.
This solution has enabled the customer to assign to the operator only mould cleaning, core positioning and casting control operations. The casting process is managed by special software, thanks to which it is the robot that determines the machine pivoting speed during the aluminium casting phase and not the opposite.
Using the software developed by Tiesse Robot technicians, it is possible to simply set the characteristic casting parameters, such as the quantity of aluminium, casting speed and any balancing, waiting times, etc.
At the Gifa 2015 showcase, Tiesse Robot displays its know-how matured in almost twenty years of applying robots in aluminium foundry and in the die-casting environment, particularly in casting unloading operations. The evolution in the sector has led the company to increasingly enter the specifics of aluminium foundry process problems and become not a mere system executor, but an active player in the solutions created. Today Tiesse Robots activity consists in supplying standardised packages with “turnkey” islands, which enter the factory ready to satisfy all production requirements.
Die-Casting and Gravity Casting
Concerning die-casting, the solutions offered range from setting up robots for interlocking casting presses in more or less complex work islands, to die lubrication robots in various configurations. Tiesse Robot also covers other foundry technological-productive aspects and focuses on resolving problems present in gravity casting processes; here it is able to offer solutions hinged around Kawasaki anthropomorphic robots.
It should be remembered that Tiesse Robots ability to make proposals in automating gravity casting processes covers all industrial demands and ranges from simple islands with two or three machines to linear systems, from rotating table systems with casting and unloading robots to more sophisticated solutions with ladle changing on the casting robot for managing several aluminium alloys to robot interlocked islands with a casting arm release and piece unloading grab picking device. These technologies were also proposed to foundries of alloys such as bronze and brass, where the problems to resolve are tied to the short cycle times and the high temperatures of the alloy (in particular up to 1,300 C° in the case of bronze alloys).
Tiesse Robot also approached foundries with moulding box casting, where the possibility was found of successfully applying the basic technologies. This new automation phase turned into a productivity increase of more than 50%. As the problems of casting different alloys in successive cycles had to be resolved, we developed an automatic ladle change system, which permits taking from different furnaces, without polluting the alloys.
Tiesse Robots evolution in the Foundry and Gravity Casting sector
It was a natural evolution for Tiesse Robot to work alongside its customers to find solutions to finishing pieces requiring core deburring, cutting and flogging operations and develop work centre interlocking systems with robot equipped with vision systems for piece quality control. In fact, foundries have had to transform and evolve in relation to a market reality of supplying finished and certified products, and sometimes Tiesse Robot has anticipated this trend.
The attention of Tiesse Robots R&D division is now focussed on using and developing vision systems. These systems permit the positions of the working areas to be determined in space, regardless of form tolerances and without other precise positioning needs in dedicated equipment. At the same time, the company is perfecting off-line programming software which starting from the files transmitted by CAD or CAM systems permit the automatic generation of robot tool work trajectories and the relative orientation vectors.
Traditional programming times are totally surpassed using these extremely advanced technologies which offer the possibility of robot programming without ever stopping production; time is therefore gained in set-up times and maximum system compactness, while modularity and flexibility are ensured at the same time.