Hazardous conditions are commonplace in foundry operations, so it is no surprise manufacturers are turning to automation with robotics. Foundry robots are capable of performing a number of applications including: die casting, mold casting, sand casting, finishing, forging, and chemical cleaning. The hot and hostile environments often involved with these types of applications is no problem for foundry robots like the foundry grade FANUC R-2000ib/165F. These robots are built with heat resistant special steel to prevent any wear or failures while performing applications in the harsh environment of foundries.
One of the biggest benefits of adding foundry robots to the production floor is they eliminate the dangers humans face while working in foundries. Humans are not capable of being able to withstand the high temperatures of these operations for long periods of time. Workers are at risk of developing heat exhaustion which will not only put their health at risk but will also prevent them from doing their job properly. Possible exposure to harsh chemicals, high pressure sprays, and high levels of dust is not healthy for humans. Workers in foundries often inhale hazardous substances such as formaldehyde, metal dusts, lead, or aluminum among many others. These substances are not visible, so workers do not realize they are inhaling them. This can lead to respiratory problems and long terms impacts could cause serious illnesses such as lung cancer. Foundry robots help companies improve worker safety. Automating foundries with robots like the foundry grade ABB IRB 6640-205/2.75 removes workers from dangerous environments that can have devastating long term impacts on their health.
Not only do foundries contain tough environments, but they can also involve the lifting of heavy objects adding to the laborious scope of work. Adding a foundry grade FANUC R-2000ib/210F with its high payload capacity allows for the manipulation of heavy workpieces increasing production efficiency. It would take multiple workers to lift just one heavy object, whereas it would take just one foundry robot. For example, mold casting may involve the pouring of several hundreds of pounds of hot metal into a mold. This would take multiple workers to lift the hot metal, not to mention they may spill the liquid metal missing the mold and potentially splattering themselves. One robot can handle this task with speed and accuracy, never missing the mold and preventing the waste of materials. Foundry robots are able to replicate accuracy without any deviation in operations. This saves production costs for manufacturers as materials are not wasted and there are fewer labor expenses. The unmatched precision of foundry robots decreases cycle time meaning operations are more productive further saving on manufacturer costs.
The programmability of foundry robots gives manufacturers a wider range of flexibility in their operations. If production lines change these robots can easily be reprogrammed and redeployed to perform another application. In a time when production lines are often short lived, foundry robots allow companies to be able to quickly adjust their processes. With human workers there would need to be new training, delaying productions and adding additional costs. Not to mention workers may have a difficult time having to adjust to more harsh conditions.
Foundry robots are becoming high in demand as they are expanding the capabilities of manufacturing in hostile environments while improving efficiency, quality, and safety.