Our customer needed to increase the efficiency and productivity of the production process. With our solution, we increased production by 8% and shortened the aluminums casting processes by 4 seconds.

The problem: Our customer who produces aluminums by high pressure die casting needed to accelerate aluminums casting processes in order to increase the efficiency of production process. To achieve this goal our technician specialist had to solve the question of shorten application time of form lubrication. One of the robot picks the product out from the form when the casting process end and the second robot starts lubricate the form. Lubrication can only begin when it is verified that the product has really left the form to prevent the other robot does not erase the product. The checking process was applied during the processing process of the product. From the point of view of efficiency it was too late. The customer wanted a solution that confirms product removal immediately after catching by robot to start the lubrication process.

The solution: Our technical specialist suggested the installation of mechanics bound with Transit Time Sensors to the robot’s hand, which picks out the products from forms. The signals are transferred to the evaluation system using relay logic. These processed signals are provided to the robot control system and the system immediately knows if the product is or is not placed in the form.

Used product: Transit Time Sensors from Wenglor sensoric GmbH is insensitive to gloss in the background and assures reliable switching performance for reflective surfaces and reflectors within the working range. Edges are even accurately detected at high process speeds. This is assured by the small laser spot and the high switching frequency of up to 1000 Hz. WinTec makes it possible to install sensors directly next to each other, and even directly opposite each other, without any reciprocal influence. Our technical specialists also designed adjustable sensor holders, transmitter passive box connectors and output signal evaluation by using relay logic module.

The using benefit: With our solution the customer saved four seconds for each casting cycle and it helped to increase the production from five to eight percent. This solution accelerated the aluminum casting process and ensured the efficiency of the production process. The customer was very satisfied with the offered solution.