Robotic automation for the deburring of cast iron castings: our solution at Valme
The project originated from the need to automate the finishing of special cast iron components for Valme, a manufacturer of concrete distribution systems.
Introduction
The project had to take into account the specific properties of the component material – special cast iron alloys – characterised by extremely high hardness and mechanical strength.
Objective
The primary objective was to transition from a manual process, which was highly taxing for the operator, to a high-efficiency robotic system.
Project Challenges
The sprue cutting and deburring phases present unique technical challenges, addressed through thorough engineering analysis:
- Health and Safety: Eliminating burdensome manual tasks in dusty and noisy environments was the customer’s absolute top priority.
- Material Hardness: The hardness of the alloy placed significant strain on the cutting and deburring systems.
- Thermal Sensitivity: The material requires precise management of cutting speeds and tool pressures.
The Technological Solution
The robotic cell implemented is a concentration of state-of-the-art technology, designed for maximum flexibility:
Advanced Robotics
Use of ABB robots equipped with the most advanced technological packages for mechanical machining, ensuring path precision and force control.
3D Vision
An integrated 3D scanning system allows the robot to recognise workpieces during pick-up, managing the orientation and handling of components autonomously.
Configurable Tool Magazine
The cell features automatic tool change with a customisable magazine, enabling cutting discs to be alternated based on the selected recipe.
Results and Benefits
The implementation of the cell radically transformed our customer’s production department:
Multi-shift efficiency
Operational Flexibility
Simplified Programming
Social Sustainability
“A radical change that puts people at the centre”
The Added Value: Technical Excellence and Innovation
This challenge drove us towards intensive research in the field of robotic machining, contributing to improving our customer’s operations through the development of cutting-edge solutions for the removal of resistant materials.
The entire system was designed with an Industry 4.0 mindset: the architecture implemented enables data exchange between the machine and management systems, making the production process interconnected, traceable and optimised.
