Robotic cell for deburring forge and foundry pieces

In 2011 Aldakin finished a R&D project to create a robotic cell for deburring forge and foundry pieces with a high degree of satisfaction.

This robot works with big size and hardness pieces of forge and foundry. This is a new bet from Aldakin in the field of robotic cells that fills an important gap in the market of foundry and forge sector. Nowadays lot of industries still perform these operations manually.

The project has combined the technologies of robotics, artificial vision and communications in order to achieve the maximum comfort for customers. The deburring process is fully automated with savings in time over 60%, and the programming of new pieces is very agile due to the data acquisition via CAD files, which is a standard for many industrial design departments.

At the end of 2013, Getting Robotika was founded as a specialized Spin-off of Aldakin in this kind of robotic cells.

The experience in automation and robotics for productive processes, the contact and relation with companies related directly or indirectly with this market and the previous know-how were the backbones of the new company.

Aldakin joined knowledge and technology, providing two technicians with huge experience in robotics, with financial support coming from START UP CAPITAL NAVARRA and CAIXA CAPITAL RISC.

This cluster provides Getting the necessary support to be a solid an innovative company that aims to be in the forefront of foundry and forge robotics.

Getting is located in Alsasua with an industrial facility over 1500m2 for industrial use and more than 400m2 for offices.

Getting offer three standardized cell types depending on the size of the piece:

• KUME DBR PH110. For very big pieces. Between 1-50 tons.
• KUME DBR PE110. For medium size pieces. 100Kg to 3 tons.
• KUME DBR PT110. Small pieces. 20Kg to 200Kg.

However Getting can adapt these standards to customer specific requirements in product and process, thus se can customize the product to the demands.

The robotic cells will market in three different options: sale, rent and leasing.

Getting also offer additional services like surveillance and maintenance 24/7 by remote connection, so our customers have full coverage during the operation of the cell. Technical support in situ is also provided.

During cell lifecycle customers usually add new references to their processes, Getting offer also the reprogramation of the cell.

The robotic cells built by Getting Robotika have great advantages over manual operations due to the integration of artificial vision, compensation systems and software based on adaptive control algorithms.

Almost all the companies of foundry have manual or semimanual operations for deburring. Few of them have some automation processes, and always related to planar faces or parallelepiped pieces.

Manual operations have the following disadvantages:

• Non homogeneous deburring.
• Drudgery with occupational hazards.
• Great variability in cycle time.

Several companies outsource this process accepting the following added difficulties:

• Shipping/receipt of the pieces. Administrative and logistic work.
• Transportation costs.
• As they are not integrated in the process, that imply Increase of cycle times and loss of control.

There are diverse foundry companies, they work with different raw materials depending on the sector of their customers. We can cite automotive, wind power, energy, valves, railway, shipbuilding, chemical, oil & gas and water treatment, among others.

Taking into account the variety of markets, sectors, customers and applications; the foundry pieces can vary a lot respecting to shapes, sizes and complexity level.

Therefore, a company in this market needs to cope with lots of references, so they need a product like this, with simple and fast programing. Moreover, it is possible to have variability among a single reference, so fixed path methods are not usable anymore.

With big pieces it is almost impossible to assure their position is always the same.
The product of Getting Robotika offers clear advantages:

• Artificial vision allows trajectory modification.
• The software compensates all the initial variability (piece, position) so an homogeneity of the final product can be assured.
• Improves the productivity ratios of direct workers.
• Improves labour conditions.
• Offers a ROI over 14% compared with manual operation.