The KUKA titan at Georg Fischer Mettmann is the first robot ever used to cast molten iron.
Georg Fischer AG was established in 1802 and its Mettmann plant has a history stretching back more than 100 years. Georg Fischer Mettmann forms part of the GF Automotive division of Georg Fischer AG with its headquarters in Schaffhausen/Switzerland.
Starting point / Task definition:
Georg Fischer AG was looking for a technical solution for pouring the extremely hot and molten iron into the molding boxes at any point, thereby achieving the greatest possible flexibility and exploiting the molding boxes to the full.
Implementation / Solution:
By using two KUKA KR 1000 titan heavy-duty robots for casting the molten iron, Georg Fischer has achieved flexibility and is able to exploit the mold area to optimum effect. Now, the pouring system no longer dictates where the castings are allowed to be, and where not. Two KR 1000 titan robots work in parallel in the solution developed by the integrator ROBOTEC Engineering GmbH. A heat-resistant suit additionally protects the robot against the extremely hot conditions within the foundry.
The KUKA KR 1000 titan F offers a highly compact design and comparatively low weight of 4,700 kg. In addition, it can be integrated into complete Systems without requiring expensive special foundations and can withstand very high payloads of about 950 kg. It is not only able to lift exceptionally heavy loads, but also to position them with utmost precision. It is also able to bridge distances of up to 6.5 meters with ease. Its strength lies in its compact design, which optimally utilizes the workspace and allowed space-saving and cost-efficient integration into the system.
Results / Benefits:
Since the two robots are able to return process iron to the casting furnace in which the iron is heated back to the casting temperature, Georg Fischer not only reduces its energy and logistics costs, but also sustainably cuts its CO² emissions.