Manipulators for Handling Steel Mesh Baskets into Furnaces

Task

The company STROJMETAL KAMENICE, a.s. Konsorcium from the Czech Republic is a manufacturer of aluminium alloys for the automotive industry. The main target of this project was to rapidly increase the productivity of the heat processing technology of pressed parts for the automotive industry. The end target was to create an automated workplace with furnaces, that are operated by fully automatic manipulators.

Solution

The production cell consisted of six furnaces that are serviced by two Güdel FP-7 area Gantries. The furnaces are in a pit and the Baskets of maximum weight 1400kg are inserted one by one from above to every single furnace by the Gantry. Because of the high temperature in the furnaces (ca 250°C),  the construction of the Basket Manipulator is specifically designed for use in this environment and vertical axis is made from steel. The Manipulator is fitted with additional bronze wipers to ensure cleaning of the guideways. Each Furnace can hold four Baskets and when full, the lid is closed and the heating process takes place.
The complete cell also acts as a storage facility for the supply of Baskets filled with components before the heating process and for temporary storage of Baskets with pressed parts that have already completed the process. This storage area is serviced by a 3-axis GUDEL FP-7 Gantry with a standard vertical axis manufactured from aluminium alloy and also incorporates a rotation axis for Basket orientation. Baskets are stored in pairs on the floor one on top of the other, in specific positions and the Gantry is supplied with a vertical axis stroke of 2300 mm to enable this to take place.

Scope of supply

2x Modul FP-7 with axis strokes of X=7,250 mm, Y=7,600 mm, Z=2,400mm with steel vertical axis for insertion into furnaces
1x Modul FP-7 with axis strokes of X=21,750 mm, Y=5,700mm, Z=2,300mm with standard vertical axis and rotation axis

Result

By creating an automated workplace incorporating three GUDEL FP-7 area Gantry systems, a substantial increase in productivity, an increase in quality due to reduction in human errors, plus a significant labour saving over a 3 shift working pattern has been achieved.
The solution has created a system that ensures first class production in a world class workplace.