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1 Project Requirements

Application type: aluminum alloy gravity casting, molten aluminum temperature: 550°C.

2 Description of the overall scheme

Robot casting automation is a combination of the customer's existing equipment (2 holding furnaces, 5 casting machines), 1 FANUC R-2000iC/165F robot (including servo-driven pouring mechanism and base), 1 set of descaling device, 3 sets of manual loading and unloading safety channels, safety doors, safety fences and electrical control system integration. The following is an introduction to the systems and main equipment referenced in this solution.

This Excel spreadsheet is provided by FANUC as an aid to determining the Wrist Load conditions of particular robots.

Every effort has been made to ensure that the spreadsheet data and formulas are correct, but FANUC does not guarantee that it is free of errors.

There may be some error margin between the load calculation result of this Excel file and the load calculation result of the robot controller.

The value of the gravitational acceleration used to calculate from V7.20 of the Excel file is changed from 9.81 to 9.8. Therefore, there is some error margin between the load calculation result of the Excel file on the previous version, 

the load calculation result of the robot controller, and the load calculation result from V7.20 of the Excel file.

The principle of the pilot operated check valve is similar to that of the pressure holding valve, the exhaust port also needs to be vented before it can be opened, and if the air is cut off, the exhaust port will automatically close to prevent the cylinder from falling.

Just studied Japanese and German robots in the workshop, and found that slightly larger robots, J2 will be equipped with a balance cylinder, Japanese FANUC robot uses spring type balancing, German KUKA uses hydraulic type (diaphragm accumulator) or counterweight block method, I personally think that hydraulic (diaphragm accumulator) way is the best, the output is basically constant, and it occupies little space.

1 Project overview

1.1 Customer requirements

Use industrial robot to complete the automatic loading and unloading of spinning machine.

1.2 Actual situation

The raw material is disc-shaped, the workpiece is a circumferentially symmetrical rotary body, diameter: φ215mm Height: 7.3mm Weight: about 2kg. 

Part name: Reducer shell

Using spinning machine, the disc material is spin-formed into the reducer shell.

1.3 Note

In order to ensure the feasibility of the solution and the continuous and stable production of the automation cell, your company should meet:

1. System workflowThe spinning machine should have an I/O signal output function, which can be automatically controlled by transformation. The spinning machine top plate action can be controlled by an external signal, and the ejection speed and position can be adjusted. In order to ensure the stability of production, the equipment provided by customer should be able to operate stably, otherwise any problems caused by this will be solved by customer.
2. The blank is manually brushed and placed on a conveyor line, which transports it to the end V-shaped positioning, and then the jacking cylinder lifts it up. claw is suitable for workpieces within a specific size (robot grasping position size), if the workpiece size difference is large, you can do a series of claws or replace finger blocks and fingers.

2 Solution

The automatic loading and unloading project of spinning machine is composed of one spinning machine (on-site modification), one FANUC M-710iC/45M robot (including claw and base), one loading conveyor line, one unloading conveyor line, safety gate, safety fence and electrical control system integration. In order to meet the requirements of robot feeding, the spinning machine equipment must be mechanically and electrically modified, and the main transformation tasks involve manipulators, electricity, gas, oil circuits, etc. The following describes the systems and major devices referenced in this solution.

When you mention industrial robots, you will think of intelligent manufacturing, which always gives people a feeling of being high technology, but do robots really belong to high-end manufacturing?

I was shocked to see a map of the excavator's operating range, which was almost exactly the same as the 6-axis robot's range of action.

Robots are not omnipotent, the more projects you do, the more you feel the limitations of the robot, not as powerful as we think, robots are generally used in occasions where the accuracy is not high, such as handling, welding, painting, etc., and for cutting, assembly, etc. is not enough, the root cause of this problem is that the accuracy of the robot repeat path is too low, far less than the manipulator or linear module.

Before we engaged in a cutting project, the cutting tool was fixed at the end of the robot, and the robot was used to complete the cutting, but when the actual execution was performed, it was found that the trajectory of the robot cutting was crooked, not a very straight line at all, and the expected effect was too different.

This is a brake disc machining production line made by FANUC in Japan, in which the robot adopts an upside-down way, the robot pipeline package is fixed through a cantilever beam, is there any benefit to this fixing method, why not directly fixed on the robot boom?

When the robot cell is laid out, the equipment is generally not placed directly behind the robot, because the range of motion of many robot J1 axes is only -175 ° ~ +175 °, that is, the robot J1 axis cannot rotate 360 °, there is a blind zone of 10 °, but is there any loophole in this explanation?

Gear hot die forging automatic production design scheme, according to the production process, product characteristics, existing equipment and other conditions, design a fully automatic forging production line.