DIE CASTING GRAVITY CASTING PERMANENT MOLD CASTING LOW-PRESSURE DIE CASTING SAND CASTING FORGING KUKA ROBOTS FOR THE FOUNDRY AND FORGING INDUSTRY

WORKING IDEAS

ESCALATORS CYLINDER HEADS ALUMINUM WHEEL RIMS ENGINE BLOCKS Automotive plants, steelworks, foundries, forges. With its diversity of robot types, KUKA has established itself in the wide-ranging foundry market. Even lighter, even more flexible, even more compact – and specially adapted 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.

KUKA offers a wide range of shelf-mounted and heavy-duty robots that can

Loading and unloading

be mounted either on the floor or on the ceiling, making them the most

Safe and rapid unloading of both small parts

multifunctional and flexible foundry robots on the market. KUKA robots can

and complex castings from a die-casting

contribute to rationalizing cost-effective automation solutions in all areas of

machine.

the foundry and forging industry. Whatever the application, be it loading

KUKA robots can, of course, also carry out

and unloading of die-casting machines, deflashing presses or machining

the precise loading and unloading of finish-

centers; spraying; finishing processes, such as milling, sawing and grin-

ing centers, deflashing presses, forging ham-

ding, or handling hot, heavy forgings: KUKA will supply just the right robot

mers and drop forges.

to meet your every need – even for applications in harsh ambient conditions. The high quality and availability of KUKA robots will significantly boost your productivity.

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KUKA ROBOTS FOR EVERY EVENTUALITY

Spraying of parting agent

Handling

Finishing work

Precise contour spraying results in the opti-

Assembly and handling of sand core parts.

Precise removal of sprue and flash. The stiff-

mized thermal economy of the die, ensuring

Neither the assembly of delicate core parts

ness of KUKA robots allows accurate sawing

high quality castings which can also lower

nor the handling of complex cores poses

and milling along precisely defined paths.

cost due to reduced parting agent consump-

problems for a KUKA robot.

KUKA robots grind and polish castings and

tion and the use of simpler dies.

sand cores with the utmost precision.

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PRODUCTIVE MODULAR TIME-SAVING EFFICIENT VERSATILE 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...

… and the benefits for you

➔ Compact robot arm

➔ Ideal combination of high payload capacity and small footprint

➔ Small footprint

➔ Fast and reliable – even for complex tasks

➔ Low weight of robot

➔ Availability: nearly 100 %

➔ Payload capacities from 16 to 570 kg

➔ Optimized cycle times

➔ Greater work envelope depth, both forwards and upwards

➔ Process reliability

➔ PC-based controller

➔ Assured productivity ➔ Easy integration of peripheral devices,

… and shelf-mounted robots… ➔ Low height

➔ Flexible range of applications

➔ Robot “knee” moved forward and downward

➔ Compact cell layout

➔ Greater work envelope depth, both forwards and downwards

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e.g. deflashing presses, end of arm tooling

THE 3D ADVANTAGE

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 aluminum spatter, molten material or sand, and plays a major role in ensuring the process reliability and availability of your system.

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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 machine.

On the die-casting machine

Next to the die-casting machine

Inverted installation in front of die-

KUKA shelf-mounted robots can be installed

Installation of the unloading robot from the

casting machine

on top of die-casting and injection molding

non-operator side of machine allows a process-

The suspended installation of the KUKA robot

machines or machine tools to save space, thus

optimized cell layout.

in front of, next to or above the machine allows even more flexible system concepts.

allowing compact system concepts. In the next to the machine mounting position, Positioning the robot on top of the machine

non-productive time can be used effectively for

The advantage of this kind of installation is

leaves the machine highly accessible and al-

machining, significantly boosting productivity.

the optimal utilization of space and non-pro-

lows time-saving unloading processes to be

The key to this is the flexibility and mobility of

ductive times, and the high availability that

carried out with the safety gates closed.

the compact, 6-axis KUKA robot, whose work

can be attained by 6-axis robots, even in the

envelope can optionally be extended by means

automation of large machines.

You can exploit the flexibility of the robot for

of an additional linear unit.

cooling tasks or parting agent applications.

This position is particularly suitable for com-

This ensures an accurate and finely-dosed

pact new installations and for subsequent

spraying process, particularly in the case of

automation of existing system concepts.

complex dies.

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➔ Space-saving

➔ Compact cell layout

➔ Compact and flexible cell concepts

➔ High availability

➔ Flexible installation position

➔ Ideal utilization of non-productive times

➔ Flexibility

➔ Optimal utilization of non-productive times

➔ Process reliability

➔ Short unloading times

➔ Automation of existing system possible

➔ Large to very large clamping force ranges

➔ Unloading possible with safety gate closed

➔ Good accessibility

➔ Good accessibility

NOTHING IS IMPOSSIBLE

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.

Die casting KUKA robots have established themselves in the die-casting industry by optimally combining payload capacity and space requirement. Their flexible application potential, either by or on the die-casting machine, standing or inverted, makes a customized and compact cell layout possible. Forging KUKA robots with Foundry equipment are particularly suitable for use in forges, as they maintain consistently 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 payload capacity, reach and precision. The KUKA PC controller allows the use of flexible end of arm tooling systems whose drives can be programmed 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 cast ing molds or low-pressure die-casting systems.

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FLEXIBLE FAR-REACHING POWERFUL 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 payload 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.

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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

1.220

47,9

KR 60 L30-3 F

2.894

3.795

2.429

1.445

983

1.480

1.220

47,8

KUKA SHELF-MOUNTED ROBOTS

Configuration example based on a KR 60 L30-3 KS-F shelf-mounted

Standard robots:

robot

– 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 Arm extension (200 or 400 mm)

➔ Heat-resistant and heat-reflecting special paint finish – Included in the standard package: Pressure regulator which prevents the

In-line wrist with arm extension, protection rating IP 67, Foundry version

penetration of water or dust by generating an overpressure in the arm housing

Up to 2628 mm reach

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MODULARITY FOR ADDED VALUE – KUKA SHELF-MOUNTED ROBOTS ARE FLEX Interfaces

Controller

Robots

Low payloads KUKA KCP

Energy supply unit on axis 3

KUKA KR C2

Medium payloads

Energy supply systems

High payloads

Additional options,e.g.

External periphery, e.g. linear

HMI Studio, KUKA.PLC

robots, assembly stations

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 delivery 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.

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XIBLE IN THEIR RANGE OF APPLICATIONS Modular components

Reach

Horizontal Vertical

Module

Machines

1.801 mm 1.105 mm Wrist

Recommended Payload

16 kg

KR 16 KS-F

for die-casting machines up to 500 t

Reach

Horizontal Vertical

Module

2.233 mm 1.402 mm Wrist

2.433 mm 1.600 mm Arm extension 200 mm

2.628 mm 1.800 mm Arm extension 400 mm

Recommended Payload

Reach

30 kg 45 kg 60 kg

Horizontal Vertical

Module

KR 30-3 KS-F

for die-casting

KR 60 L30-3 KS-F KR 60 L45-3 KS-F

machines up to

KR 60-3 KS-F

3.100 mm 1.575 mm Wrist

1,200 t

3.300 mm 1.775 mm Arm extension 200 mm

3.500 mm 1.975 mm Arm extension 400 mm

3.700 mm 2.175 mm Arm extension 600 mm

3.900 mm 2.375 mm Arm extension 800 mm

Recommended Payload

100 kg 110 kg 130 kg 150 kg 180 kg 210 kg

KR 180 L100-2 K-F KR 210 L100-2 K-F

KR 150-2 K-F KR 180-2 K-F KR 210-2 K-F

KR 150 L110-2 K-F KR 150 L130-2 K-F KR 180 L130-2 K-F KR 180 L150-2 K-F KR 210 L150-2 K-F KR 210 L180-2 K-F

for die-casting machines over 1,200 t

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.

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SUPERIOR ON THE FLOOR, TOO – KUKA ROBOTS ARE FLEXIBLE IN ANY POSI Interfaces

Controller

Robots

Low payloads KUKA KCP

Energy supply unit on axis 3

Medium payloads

KUKA KR C2

Energy supply systems High payloads

Heavy payloads Additional options, e.g.

External periphery, e.g. linear

HMI Studio, KUKA.PLC

robots, assembly stations

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.

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ITION Modular components

Reach Module

Horizontal

Machines

1.611 mm Wrist

Recommended Payload

16 kg

for die-casting

KR 16 F

machines up to 500 t

Reach Module

Horizontal

2.033 mm Wrist

3.102 mm Wrist

2.230 mm Arm extension 200 mm

2.429 mm Arm extension 400 mm

Recommended for die-casting

Payload

Reach Module

16 kg 30 kg 45 kg 60 kg

Series 2000

KR 30 L16 F KR 30-3 F

KR 60 L30-3 F KR 60 L45-3 F

machines up to 1,200 t

KR 60-3 F

2.700 mm Wrist

2.900 mm Arm extension 200 mm

3.100 mm Arm extension 400 mm

Recommended Payload

110 kg 130 kg 150 kg 180 kg 210 kg 240 kg

Reach Module

KR 150-2 F KR 180-2 F KR 210-2 F KR 240-2 F

2.826 mm Wrist

KR 150 L130-2 F KR 180 L150-2 F KR 210 L180-2 F KR 240 L210-2 F

3.076 mm Arm extension 250 mm

KR 150 L110-2 F KR 180 L130-2 F KR 210 L150-2 F KR 240 L180-2 F

for die-casting machines up to 3,000 t

3.326 mm Arm extension 500 mm

Recommended Payload

240 kg 280 kg 340 kg 360 kg 420 kg 500 kg

KR 360 L240 F KR 360 L280 F KR 500 L340 F

for die-casting machines up to 4,500 t

KR 360 F KR 500 L420 F KR 500 F

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PROGRAM CONSULT CONTROL SIMULATE TRAIN SUPPORT KUKA control technology makes operator control of your robot easy. Integration into higher-level control structures is no problem. Special offline and simulation programs shorten start-up times and help you to optimize your custom programming.

Offline programming

Simulating applications

Simple operator control

Easy programming with

with KR C Office

with KUKA Sim

with the KUKA KCP

the KUKA KR C

With KR C Office, you can pro-

With KUKA Sim you can create

The KCP combines simple

The robot controller can be

gram your entire process off-

a simulation of your entire ap-

operator control with rapid

programmed easily thanks to

line. The advantages: production

plication. This enables system

programming: template forms

its Microsoft Windows inter-

can

uninterrupted.

concepts, processes, cycle

and simple menu-guided pro-

face. It is expandable, can be

Conversion time is minimized.

times, reaches, collision checks

gramming make it easy to in-

integrated into networks via a

Newly created programs can be

and offline programming to be

put commands; the 6D mouse

bus, and contains ready-made

used without modification.

tested in a targeted manner

can be used to move the indi-

software packages – impor-

and, if required, optimized be-

vidual robot axes intuitively

tant factors for the automa-

fore commissioning.

and to save the corresponding

tion of the future.

continue

coordinates directly.

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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.

Commissioning

Production

Customized user interfaces, application soft-

We optimally integrate custom software mo-

Programming, optimization, immediate assis-

ware, offline programming, simulation, cycle

dules, sensors, vision systems and robot tools,

tance – with KUKA, the availability of your

time analyses, feasibility studies – even in the

carry out load analyses while the program is

systems is in the best of hands. Let us prove

planning phase KUKA will provide you with

running, and give you advice, support and in-

it: with remote diagnosis, on-site servicing,

whatever you need to ensure that your system

struction during the commissioning process

updates and upgrades, customized mainte-

will operate smoothly.

– all to help ensure that your system is cost-

nance agreements, spare and used parts, and

effective to operate right from the outset.

cutting-edge logistics…

IN

Planning

TE

G

The KUKA partner network

R R AT O

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

N U FA C T U

and innovative end customers is one of the cornerstones of KUKA’s success – and a constant

R

OT

RE

ER

MA

END CUSTOMER

close cooperation with industry specialists, die-casting machine manufacturers, system partners challenge to optimize our solutions still further. Thanks to this expertise in creating custom solutions, and a dense network of regional training and service centers, KUKA has earned an outstanding reputation in the foundry and forging industry.

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KUKA R O

B

WM-Nr. 841891/D/1/02.05 No liability accepted for errors or omissions.

CONTACT INFO ADDRESSES

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 Robotics Corp. 22500 Key Drive Clinton Township Michigan 48036 United States of America Tel. +1 586 7959090 Toll free: 866 8735852 Fax +1 586 5692087 [email protected]

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

www.kuka.com