The information package put together by KUKA Roboter GmbH, Augsburg, for GIFA 2003 (16 to 21 June) in Düsseldorf is also molded to your needs. Forming the centerpiece at KUKA stand D38 in Hall 17 are two robotic applications for foundries. In one of the example applications, from the Italian KUKA systems partner COPRAS, a KR 150F sets up a permanent mold casting while the newly-developed KR 16F cleans the necessary ladles. In the other application, a shelf-mounted KR 150K and a KR 150 standard robot also work together in perfect coordination. While the KR 150K, mounted on a die-casting machine, sprays parting agent, the KR 150, mounted on a covered linear unit, handles the castings. Other applications using KUKA robots are being presented at the stands of twelve KUKA partners.

When it comes to robotic automation for foundry applications, KUKA Roboter GmbH is considerably ahead of the usual state of the art. This is borne out by the fact that KUKA has the largest product range on the market, including standard, shelf-mounted, heavy-duty and palletizing robots. These have a reach of up to 3,700 millimeters and an extraordinary payload capacity range, from 16 to 210 kilograms in the case of shelf-mounted robots and up to 500 kilograms for standard robots. Whatever the foundry application, there is always a KUKA robot that can be cast for the part.

KUKA develops the individual solutions in cooperation with industry specialists, so they are always exactly tailored to the user’s requirements. The user thus profits from optimized processes and therefore greater productivity and cost-effectiveness. One example of KUKA’s optimized engineering is the in-line wrist, designed for protection rating IP 67, which can withstand temperatures of up to 100 °C in continuous operation, or even 180 °C for up to 10 seconds every minute. The in-line wrist is manufactured using corrosion-resistant materials, is fitted with seals and has special heat-reflecting paintwork. KUKA places great importance on the correct paintwork in any case. Robots destined for foundry applications thus always receive a triple coat. This has a very good final hardness, is impact-resistant and hard-wearing, is resistant against both acids and alkalis, and can briefly withstand temperatures of up to 220 °C. Seals protect the robot arm against dust. Robots used in spraying applications are also fitted with a pressure regulator to protect them against aggressive media that might otherwise penetrate from outside.

The range of possible applications for KUKA robots in foundries is highly diversified. Robots are used to load and unload injection molding and die-casting machines and can also be compactly mounted on top of the machines, where they spray variably-dosed quantities of parting agent onto the tool. They also check the parts they have removed from the mold. Finishing tasks performed by the robots include deburring, milling, sawing and sprue removal. At the end of the process, the robots set the workpieces down or palletize them.

If the work envelope of a KUKA robot, large as it is, is insufficient for a combination of several different applications, it can be significantly increased using a linear unit adapted by KUKA to the requirements of the foundry industry. In this case, an additional traversing unit is mounted on the ceiling or on the floor and a cover is installed, protecting it from dust, swarf and aluminum spatter.

KUKA Roboter GmbH is an IWKA Group company and ranks among the world’s leading manufacturers of industrial robots. Core competencies are the development, production and sale of industrial robots, controllers, software and linear units. In 2002, the company achieved total sales of more than 250 million euro, with an output in excess of 7,500 robots.