Preparing hot, 30-pound aluminum ingots for
storage is challenging work, but it’s even
harder when you have to deal with outdated
equipment that runs too slowly and breaks
too often.
Such was the case for this client, a major
recycler of aluminum for the automotive industry.
MMCI was challenged to develop a strong and
rugged end-of-line packaging solution that
could align the ingots, stack them, weigh
them and then bind them for transport and
storage.
Plus, the system would need to operate at
a much faster speed than the current system
and withstand the high temperature environment.
After evaluating the entire process, MMCI
engineers determined that they could design
a robotic unitizing cell featuring a Fanuc
M410ic robotic arm along with innovative upstream
and downstream solutions.
In order to increase the system’s capacity,
MMCI had to first optimize the upstream process.
The ingots entered the system from a cooling
bath and then needed to be aligned for stacking.
This was an engineering challenge since the
placement of the trapezoidal shaped ingots
would have to alternate for each row.
To accomplish this, MMCI engineers developed
an inline system that would center, flip and
align each layer of ingots for transfer by
the robotic arm.
The system features a rugged chain conveyor
with a smooth, consistent surface that allows
the ingots to accumulate at the end of the
line.
The team then created individual processes
for centering, flipping and aligning the ingots
on the fly - significantly increasing the
system’s capacity.
Next, our design team had to install high
tech laser sensors instead of standard customary
sensors in order to detect the reflective
nature of the aluminum ingots and accurately
communicate their position to the robot.
We then configured the robot’s end-of-arm
tooling with 3 independently actuated grippers
and custom channels that ensure the proper
transfer and stacking of each ingot.
Once the ingots are stacked, they move to
an inline scale that calculates the exact
weight of the unitized load and outputs a
label with this information.
To further optimize the downstream process,
MMCI Engineers developed automation to replace
the manual strapping process currently employed.
By integrating an inline strapping machine
with a lift, turn table and multiple controls,
our team was able to completely automate the
strapping process.
Multiple sensors were utilized to ensure that
all straps are properly positioned to align
with notches on the ingot.
Finally, to ensure the cell would run efficiently
in the hot, industrial environment, the robot
was outfitted with a protective suit and monitored
with inline temperature probes through a climate-controlled
cabinet certified to 120 degrees Fahrenheit.
With the new automation, loads are being unitized
fast enough to keep up with production while
the rugged design and protective features
have virtually eliminated downtime.
Plus, the inline weighing and strapping processes
have helped improve efficiency and reduce
costs.
This project represents another example of
how intelligent engineering and a focus on
automating an entire process yields game-changing
results for our clients.
