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WORKING IDEAS
KUKA ROBOTS FOR THE FOUNDRY AND FORGING INDUSTRY
DIE CASTING GRAVITY CASTING PERMANENT MOLD CASTING LOW-PRESSURE DIE CASTING SAND CASTING FORGING
2
KUKA offers a wide range of shelf-mounted and heavy-duty robots that can
be mounted either on the floor or on the ceiling, making them the most
multifunctional and flexible foundry robots on the market. KUKA robots can
contribute to rationalizing cost-effective automation solutions in all areas of
the foundry and forging industry. Whatever the application, be it loading
and unloading of die-casting machines, deflashing presses or machining
centers; spraying; finishing processes, such as milling, sawing and grin-
ding, or handling hot, heavy forgings: KUKA will supply just the right robot
to meet your every need – even for applications in harsh ambient conditi-
ons. The high quality and availability of KUKA robots will significantly boost
your productivity.
Loading and unloading
Safe and rapid unloading of both small parts
and complex castings from a die-casting
machine.
KUKA robots can, of course, also carry out
the precise loading and unloading of finish-
ing centers, deflashing presses, forging ham-
mers and drop forges.
ESCALATORSCYLINDER HEADSALUMINUM WHEEL RIMSENGINE BLOCKSAutomotive plants, steelworks, foundries, forges. With its diversity of ro-
bot types, KUKA has established itself in the wide-ranging foundry market.
Even lighter, even more flexible, even more compact – and specially adap-
ted to the needs of die casting, permanent mold casting, sand casting and
forging processes KUKA – robots offer you the right solution for any task
and any application.
3
KUKA ROBOTS FOR EVERY EVENTUALITY
Finishing work
Precise removal of sprue and flash. The stiff-
ness of KUKA robots allows accurate sawing
and milling along precisely defined paths.
KUKA robots grind and polish castings and
sand cores with the utmost precision.
Handling
Assembly and handling of sand core parts.
Neither the assembly of delicate core parts
nor the handling of complex cores poses
problems for a KUKA robot.
Spraying of parting agent
Precise contour spraying results in the opti-
mized thermal economy of the die, ensuring
high quality castings which can also lower
cost due to reduced parting agent consump-
tion and the use of simpler dies.
4
6-axis robots give you the decisive edge
6-axis robots offer many advantages over conventional gantry systems in a wide range of applications: they have a longer
life cycle, require less maintenance and ensure a quicker return on investment. Their great flexibility and mobility in 3D space
allow for the handling of both complex and delicate work pieces and the effective utilization of non-productive time.
The advantages of standard KUKA robots...
➔ Compact robot arm
➔ Small footprint
➔ Low weight of robot
➔ Payload capacities from 16 to 570 kg
➔ Greater work envelope depth, both forwards and upwards
➔ PC-based controller
… and shelf-mounted robots…
➔ Low height
➔ Robot “knee” moved forward and downward
➔ Greater work envelope depth, both forwards and downwards
… and the benefits for you
➔ Ideal combination of high payload capacity and small footprint
➔ Fast and reliable – even for complex tasks
➔ Availability: nearly 100 %
➔ Optimized cycle times
➔ Process reliability
➔ Assured productivity
➔ Easy integration of peripheral devices,
e.g. deflashing presses, end of arm tooling
➔ Flexible range of applications
➔ Compact cell layout
PRODUCTIVE MODULARTIME-SAVINGEFFICIENTVERSATILE
5
The variety of KUKA Robot applications can be extended still further using a KUKA linear unit. This can be installed on the
ceiling, floor, or on a gantry, according to your specific requirements. The result is maximum mobility and functionality for
your KUKA robots. This covered linear traversing axis, specially designed for use in foundries and forges, is safe to walk on,
and provides optimum protection against fouling of the mechanical system and the energy and fluid supply system by alu-
minum spatter, molten material or sand, and plays a major role in ensuring the process reliability and availability of your
system.
THE 3D ADVANTAGE
6
On the die-casting machine
KUKA shelf-mounted robots can be installed
on top of die-casting and injection molding
machines or machine tools to save space, thus
allowing compact system concepts.
Positioning the robot on top of the machine
leaves the machine highly accessible and al-
lows time-saving unloading processes to be
carried out with the safety gates closed.
You can exploit the flexibility of the robot for
cooling tasks or parting agent applications.
This ensures an accurate and finely-dosed
spraying process, particularly in the case of
complex dies.
➔ Space-saving
➔ High availability
➔ Flexibility
➔ Short unloading times
➔ Unloading possible with safety gate closed
Next to the die-casting machine
Installation of the unloading robot from the
non-operator side of machine allows a process-
optimized cell layout.
In the next to the machine mounting position,
non-productive time can be used effectively for
machining, significantly boosting productivity.
The key to this is the flexibility and mobility of
the compact, 6-axis KUKA robot, whose work
envelope can optionally be extended by means
of an additional linear unit.
➔ Compact cell layout
➔ Flexible installation position
➔ Optimal utilization of non-productive times
➔ Automation of existing system possible
➔ Good accessibility
Inverted installation in front of die-
casting machine
The suspended installation of the KUKA robot
in front of, next to or above the machine al-
lows even more flexible system concepts.
The advantage of this kind of installation is
the optimal utilization of space and non-pro-
ductive times, and the high availability that
can be attained by 6-axis robots, even in the
automation of large machines.
This position is particularly suitable for com-
pact new installations and for subsequent
automation of existing system concepts.
➔ Compact and flexible cell concepts
➔ Ideal utilization of non-productive times
➔ Process reliability
➔ Large to very large clamping force ranges
➔ Good accessibility
KUKA robots work perfically in any position. Depending on the specific requirements with respect to the position of the
die-casting die, trajectories, accessibility, safety and space, KUKA robots can be installed on, next to or above the ma-
chine.
7
NOTHING IS IMPOSSIBLE
Die casting
KUKA robots have established themselves in the
die-casting industry by optimally combining payload
capacity and space requirement. Their flexible appli-
cation potential, either by or on the die-casting ma-
chine, standing or inverted, makes a custo mized and
compact cell layout possible.
Forging
KUKA robots with Foundry equipment are particularly
suitable for use in forges, as they maintain consis-
tently high performance even at high temperatures
and in dirty environments.
Sand casting
The assembly of sand cores in a core assembly line
places high demands on the robot with respect to pay-
load capacity, reach and precision.
The KUKA PC controller allows the use of flexible end
of arm tooling systems whose drives can be program-
med as additional external axes. This means that it
is possible to pick up a wide range of different core
types without the need to change gripper.
Gravity and low-pressure die casting
KUKA robots enable precise and repeatable pouring of
the melting charge into permanent molds, sand cas t -
ing molds or low-pressure die-casting systems.
The range of possible applications for KUKA robots knows practically no bounds. A KUKA robot can take on a wide range of
tasks in the overall foundry process. This is because the industry-specific KUKA Foundry equipment make it possible to use
KUKA robots even in the toughest environments.
8
Work envelope A (mm) B (mm) C (mm) D (mm) E (mm) F (mm) G (mm) Volume (m3)
KR 60 L30-3 KS-F 2.330 4.130 2.628 1.445 1.183 900 1.22 0 47,9
KR 60 L30-3 F 2.894 3.795 2.429 1.445 983 1.480 1.220 47,8
FLEXIBLE FAR-REACHINGPOWERFUL CUSTOM-TAILORED DIVERSE KUKA offers you the largest product range of shelf-mounted robots, with a wide variety of reaches and work envelopes.
They can be adapted to their surroundings through the use of optional arm extensions or KUKA traversing units. The pa-
yload capacities of robots manufactured especially for use in foundries and forges range from 16 to 210 kg.
Both KUKA shelf-mounted robots and KUKA standard robots have large work envelopes. The aim of the new design of
the KUKA shelf-mounted robots was not merely to obtain a long reach forwards and upwards, but also to achieve the
maximum possible reach forwards and downwards. This was delivered as a result of the low overall robot height and the
forward shifting of the robot knee.
9
Standard robots:
– Protection rating IP 65
➔ Dust-proof
➔ Protected against waterjets
Foundry equipment for KUKA robots:
– Complete robot painted with triple coat of
two-component paint
➔ Particularly impact-resistant and hard-wearing,
resistant against both acids and alkalis
– Wrist axes:
– Protection rating IP 67
➔ Dust-proof
➔ Protected against damage from short-time
submersion in water
➔ Corrosion-resistant materials
➔ Additional seals and adhesive
➔ Heat-resistant and heat-reflecting special
paint finish
– Included in the standard package:
Pressure regulator which prevents the
penetration of water or dust by generating
an overpressure in the arm housing
KUKA SHELF-MOUNTED ROBOTS
Configuration example based on a KR 60 L30-3 KS-F shelf-mounted
robot
Arm extension (200 or 400 mm)
In-line wrist with arm extension,
protection rating IP 67, Foundry version
Up to 2628 mm reach
1 0
The advantage of KUKA shelf-mounted robots is their modular construction which begins during their manufacture: not only
can KUKA robots be used in a wide range of industries and applications, they can also be custom-adapted to any situation
– by means of arm extensions or linear units. The advantages: high availability, small number of components, and short de-
livery times.
As well as the in-line wrist, the arm extensions also have a special paint finish (a triple coating of two-component paint with a
high final hardness that is impact-resistant and hard-wearing, resistant against both acids and alkalis). The interface between
the in-line wrist and the arm extension is fitted with additional seals.
Interfaces Controller Robots
MODULARITY FOR ADDED VALUE –KUKA SHELF-MOUNTED ROBOTS ARE FLEX
Medium payloads
High payloads
Additional options,e.g.
HMI Studio, KUKA.PLC
Energy supply
systems
Energy supply unit
on axis 3
External periphery, e.g. linear
robots, assembly stations
KUKA KCP
KUKA KR C2
Low payloads
1 1
Reach Horizontal 1.801 mm Vertical 1.105 mm Module Wrist
Payload 16 kg KR 16 KS-F
Reach Horizontal 2.233 mm 2.433 mm 2.628 mm Vertical 1.402 mm 1.600 mm 1.800 mmModule Wrist Arm extension Arm extension 200 mm 400 mm
Payload 30 kg KR 30-3 KS-F KR 60 L30-3 KS-F 45 kg KR 60 L45-3 KS-F 60 kg KR 60-3 KS-F
Modular components Machines
XIBLE IN THEIR RANGE OF APPLICATIONS
Recommended
for die-casting
machines up to
500 t
Recommended
for die-casting
machines up to
1,200 t
Recommended
for die-casting
machines over
1,200 t
Reach Horizontal 3.100 mm 3.300 mm 3.500 mm 3.700 mm 3.900 mm Vertical 1.575 mm 1.775 mm 1.975 mm 2.175 mm 2.375 mmModule Wrist Arm extension Arm extension Arm extension Arm extension 200 mm 400 mm 600 mm 800 mm
Payload 100 kg KR 180 L100-2 K-F KR 210 L100-2 K-F 110 kg KR 150 L110-2 K-F 130 kg KR 150 L130-2 K-F KR 180 L130-2 K-F 150 kg KR 150-2 K-F KR 180 L150-2 K-F KR 210 L150-2 K-F 180 kg KR 180-2 K-F KR 210 L180-2 K-F 210 kg KR 210-2 K-F
KUKA energy supply units can optionally be supplied for installation on axis 3. They are available in a choice of variants:
Profibus DP, Interbus and CAN DeviceNet.
1 2
What applies to our shelf-mounted robots is just as true on the floor: whatever the nature of your application, whatever task
your robot has to perform, and whatever the ambient conditions – our robots’ modular design guarantees you the optimal
solution. The KUKA KR C2 controller makes it possible to implement complete manufacturing processes, including the most
varied of tasks, through the use of an integrated control concept.
Interfaces Controller Robots
SUPERIOR ON THE FLOOR, TOO –KUKA ROBOTS ARE FLEXIBLE IN ANY POSI
Low payloads
Medium payloads
External periphery, e.g. linear
robots, assembly stations
KUKA KCP
KUKA KR C2
High payloads
Heavy payloads
Energy supply unit
on axis 3
Energy supply
systems
Additional options, e.g.
HMI Studio, KUKA.PLC
1 3
Reach Horizontal 1.611 mm Module Wrist
Payload 16 kg KR 16 F
Reach Horizontal 2.033 mm 3.102 mm 2.230 mm 2.429 mm Module Wrist Wrist Arm extension Arm extension 200 mm 400 mm
Payload 16 kg KR 30 L16 F 30 kg KR 30-3 F KR 60 L30-3 F 45 kg KR 60 L45-3 F 60 kg KR 60-3 F
Modular components Machines
ITION
Recommended
for die-casting
machines up to
500 t
Recommended
for die-casting
machines up to
1,200 t
Reach Series 2000 2.700 mm 2.900 mm 3.100 mmModule Wrist Arm extension 200 mm Arm extension 400 mm
Payload 110 kg KR 150 L110-2 F 130 kg KR 150 L130-2 F KR 180 L130-2 F 150 kg KR 150-2 F KR 180 L150-2 F KR 210 L150-2 F 180 kg KR 180-2 F KR 210 L180-2 F KR 240 L180-2 F 210 kg KR 210-2 F KR 240 L210-2 F 240 kg KR 240-2 F
Recommended
for die-casting
machines up to
4,500 t
Recommended
for die-casting
machines up to
3,000 t
Reach 2.826 mm 3.076 mm 3.326 mmModule Wrist Arm extension 250 mm Arm extension 500 mm
Payload 240 kg KR 360 L240 F 280 kg KR 360 L280 F 340 kg KR 500 L340 F 360 kg KR 360 F 420 kg KR 500 L420 F 500 kg KR 500 F
1 4
KUKA control technology makes operator control of your robot easy. Integration into higher-level control structures is no pro-
blem. Special offline and simulation programs shorten start-up times and help you to optimize your custom programming.
PROGRAM CONSULT CONTROL SIMULATE TRAIN SUPPORT
Offline programming
with KR C Office
With KR C Office, you can pro-
gram your entire process off-
line. The advantages: pro duction
can continue un interrupted.
Con version time is minimized.
Newly created programs can be
used without modification.
Simulating applications
with KUKA Sim
With KUKA Sim you can create
a simulation of your entire ap-
plication. This enables system
concepts, processes, cycle
times, reaches, collision checks
and offline programming to be
tested in a targeted manner
and, if required, optimized be-
fore commissioning.
Simple operator control
with the KUKA KCP
The KCP combines simple
operator control with rapid
programming: template forms
and simple menu-guided pro-
gramming make it easy to in-
put commands; the 6D mouse
can be used to move the indi-
vidual robot axes intuitively
and to save the corresponding
coordinates directly.
Easy programming with
the KUKA KR C
The robot controller can be
programmed easily thanks to
its Microsoft Windows inter-
face. It is expan dable, can be
integrated into networks via a
bus, and contains ready-made
software packages – impor-
tant factors for the automa-
tion of the future.
1 5
Customer Support
In addition to custom-tailored robot systems, spare parts, robot rentals and used robots, KUKA also offers you a wide range
of services: from planning to commissioning and production – our employees support you during every phase of your project.
And our worldwide, modularly structured seminar program imparts valuable expertise – and can also provide robot cells for
training at your location.
The KUKA partner network
KUKA works together with selected specialists in various industries to implement the optimal
solution for you. These system integrators are brought together in the KUKA partner network. Our
close cooperation with industry specialists, die-casting machine manufacturers, system partners
and innovative end customers is one of the cornerstones of KUKA’s success – and a constant
challenge to optimize our solutions still further. Thanks to this expertise in creating custom solu-
tions, and a dense network of regional training and service centers, KUKA has earned an outstan-
ding reputation in the foundry and forging industry.
Planning
Customized user interfaces, application soft-
ware, offline programming, simulation, cycle
time analyses, feasibility studies – even in the
planning phase KUKA will provide you with
whatever you need to ensure that your system
will operate smoothly.
Production
Programming, optimization, immediate assis-
tance – with KUKA, the availability of your
systems is in the best of hands. Let us prove
it: with remote diagnosis, on-site servicing,
updates and upgrades, customized mainte-
nance agreements, spare and used parts, and
cutting-edge logistics…
Commissioning
We optimally integrate custom software mo-
dules, sensors, vision systems and robot tools,
carry out load analyses while the program is
running, and give you advice, support and in-
struction during the commissioning process
– all to help ensure that your system is cost-
effective to operate right from the outset.
END CUSTOMER
IN
TEGRATOR M
ANUFACTURER KUKA ROBOT
ER
www.kuka.com
CONTACTINFOADDRESSES No
liab
ility
acc
epte
d fo
r err
ors
or o
mis
sion
s.
WM
-Nr.
8418
91/D
/1/0
2.05
KUKA Robotics Corp.22500 Key DriveClinton TownshipMichigan 48036United States of AmericaTel. +1 586 7959090Toll free: 866 8735852Fax +1 586 [email protected]
KUKA offers a comprehensive range of products, with optimal solutions for every requirement and every industry.
What can KUKA do for you?
Low Medium High Heavy Special
payloads payloads payloads payloads models
from 3 to 16 kg from 30 to 60 kg from 100 to 240 kg from 360 to 570 kg Shelf-mounted robots
Palletizing robots
Press-to-press robots
KUKA international:Argentina, Australia, Austria,Belgium, Brazil, Chile, China,France, Germany, Hungary,Italy, Korea, Malaysia, Mexico,Norway, Portugal, South Africa,Spain, Sweden, Switzerland,
Taiwan, Thailand, UK, USA