Foundry Automation
Need
Handling of engine blocks in a foundry
Scania needed to increase its capacity to manufacture castings for engine blocks and cylinder heads. A new greenfield foundry was to be built. The new foundry aims to deliver 65,000 tons of castings annually in Södertälje, Sweden.
In the foundry, automation and logistics are needed to integrate the process steps after casting.
Minimal environmental impact and recycling of foundry sand are key factors for a long-term result.
Traceability is central, and product marking and quality control are very important.
Solution
Heavy Duty Automation
The solution includes development, programming, CE marking, manufacturing, assembly, and installation of 12 automation units consisting of:
- 7 KUKA TITAN KR 1000 robots
- 6 KR 600 KUKA robots
- 1 KR 20 KUKA robot
- Travel path, KL3000, for two Titan robots
- 200 meters conveyor system, MH Modules
- 14 Electric servo grippers, Zimmer
- Special plowing tools for robots to remove foundry sand
- 3D camera, Cognex 3D-A5000, for ID reading
- AI vision software, Cognex deep learning
- CGI control - ultrasonic measurement for checking casting quality
- Laser marking of DMC code
- Siemens control system
- Integration with superior MES
- Communication with additional machines:
- Foundry line
- Knockout equipment
- Rough cleaning machines
- Sand core knockout machines
- External blasters
- Equipment for traceability and CGI control
- High bay storage 2
- Pallet pickers
- Robot deburring
- Internal blasting
- Painting line
- High bay storage 3
- Packing machine
- Pallet strapping machine, ASM, https://asm.eu/se
Facts
| Customer | Scania |
|---|---|
| Production Start | 2021 |
| Industry | Automotive |
| Managed Product | Cylinder Heads, Engine Blocks |
| Product Size | 600*300*400 mm |
| Product Weight | 483 kg |
| Cycle Time | NDA |
| Serial Number | A19013 |
Result
An energy-efficient and sustainable world-class foundry
The energy usage per manufactured ton is estimated to be 50 percent lower for the new foundry compared to the current facility. The largest energy savings are achieved through improvements in the foundry process and recycling of the heat it generates.
By introducing new methods for material handling and recycling, transportation relative to the number of manufactured units is also reduced. The single largest energy saving is achieved through the recycling of the sand used for making casting molds, where 70 percent of the sand will be reusable.
