ABB Flexible Automation

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ABB in Foundry Automation

Key data 1998

• ABB Group
- Revenues: USD 35 billion
• ABB Flexible Automation
- Revenues: USD 1.6 billion
• Foundry Automation
Main focus downstream aluminium
From cast-houses to finished parts
- Revenues: USD 70 million
- 750 robots a year

ABB Flexible Automation

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Thirty Years in Foundry Automation

• First robot to an ABB foundry

already 1969
• 25 robots in operation in ABB´s
foundries by 1972
• 6,000 ABB robots installed in
foundries 1999
- 3500 High Pressure Die Casting
- 1500 Gravity Die Casting
- 1000 Sand Casting

ABB Flexible Automation

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ABB Foundry Business

Number of robots

300 425 500 675 750

1994 1995 1996 1997 1998

ABB Flexible Automation

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Growing Aluminium in Automotive

Driving forces
• Lower fuel consumption
• Workable recycling
• Lower aluminium price

Indicators
• Global change from iron/steel to aluminium
• 50 new large plants per year
• 50-100 major foundry expansions
per year
• Robotized automation of foundries
established

ABB Flexible Automation

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Rapid Increase in Aluminium Castings

Yearly growth 300 000 tons

Million tons

10

1991 1996 1999 2013

ABB Flexible Automation

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Focused Casting Processes

Casting Lines
High Pressure Die Casting Gravity and Low Pressure
Die Casting

ABB Flexible Automation

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Focused Automotive Parts

• Cylinder Heads
• Engine Blocks
• Engine Parts
• Transmission Parts
• Subframes
• Security Parts
• Aluminium Wheels
• Body Parts
• Aluminium Ingots

ABB Flexible Automation

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Automotive Captive Customers

ABB Flexible Automation

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Automotive Subsupply Customers

• A-CMI, Norway • Meridian, Canada

• Ahresty, Japan • Montupet, France
• Alcoa, USA • Mössner, Germany
• Alusaf, South Africa • Reynolds, Canada, USA
• Enkei, Japan • Ryobi, Japan, USA
• Fuchs, Germany • Superior, USA
• Honsel, Germany • VAW, Germany, UK
• J L French, USA, UK

ABB Flexible Automation

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Comprehensive Foundry Robot Program

• IRB 140 Foundry

• IRB 2400 Foundry
• IRB 4400 Foundry
• IRB 4400 Shelf Foundry
• IRB 6400 R Foundry
• IRB 6400 Shelf Foundry
• Controller Foundry
• Track Motion Foundry
• Cleaning tools

ABB Flexible Automation

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Foundry Product Adaptions

• High tightness
• Special coating
• Resistant to aluminium spits and
flashes
• Heat resistant
• Steam washable
• Water cooled
controller
• Foundry adapted software,
FoundryWare

ABB Flexible Automation

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FoundryWare

• ExtractWare High Pressure Die Casting

• SprayWare High Pressure Die Casting
• FlashWare High Pressure Die Casting,
Gravity Die Casting
Sand Casting
• CastWare Gravity Die Casting

ABB Flexible Automation

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Foundry Market Approach

Products and Systems

provided by ABB
• High Pressure Die Casting
• Gravity Die Casting

Systems with ABB robots provided

by Partners
• High Pressure Die Casting
• Gravity Die Casting
• Sand Casting
• Brass Casting

ABB Flexible Automation

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ABB Foundry Application Centers

Die Casting
• Germany
RobExtract,
RoboSpray and RobInsert

• Switzerland
RoboFlash

• Sweden
RoboJet

• USA, Rimrock
RobExtract,
RoboSpray, RoboFlash

ABB Flexible Automation

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Application Packages for
High Pressure Die Casting

Large Die Casting Machines RoboFlash

RobExtract

RoboSpray

RoboJet

RobInsert

ABB Flexible Automation

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Application Packages for
High Pressure Die Casting

Small and Medium Sized Die Casting Machines

RoboSpray RoboFlash

RobExtract

ABB Flexible Automation

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Application Package for
Aluminium Casting

Casting

RoboCast

ABB Flexible Automation

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Application Packages for
High Pressure Die Casting

Skimming Stacking

RoboSkim RoboStack

ABB Flexible Automation

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ABB Partners

• Acheson • Idrapresse • Pomac

• Buehler • Italpresse • Prince
• Bula • Kurtz • Remetal
• GF DISA • KWC • Rimrock
• Ellison • Laempe • Toshiba
• Fata • Loramendi • Vulcan
• Fill • Mapos • Weco
• Frech • Mecana • Wollin
• Gautshi • Mueller • Yxlon
• Hottinger Weingarten • UBE
• Mössner

ABB Flexible Automation

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Application Packages
Supplied by Partners

RoboShell

Rob X-ray

RoboFoam

RoboGrind

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Honsel, Germany

• Die Casting Machine GDK 2000

from Müller-Weingarten, Germany
• Four-cylinder in-line engine block
and transmission housings
• Workpiece weight 20-30 kg
(engine blocks)
• ABB robots on track motion
• Feed, insert, unload (RobInsert,
RobExtract), spraying, sawing and
handling devices

ABB Flexible Automation

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GM Brazil, São Paulo

• Transmission House Castings

• 3 Die Casting Machines from
Bühler
• 12 ABB robots
- 5 IRB 6400
- 4 IRB 4400
- 3 RoboSpray
• Requested output: 1480 deburred
castings in 40 hours

ABB Flexible Automation

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VAW, Cross Green, UK

• Aluminium Cylinder Heads

• Land Rover five-cylinder turbo-
diesel engine
• 19 ABB robots at the VAW Group
• First installed 1995
• Casting
• Handling
• Deflashing

ABB Flexible Automation

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A-CMI, Lista, Norway

• Strategic alliance between Alcoa

Aluminium and CMI-international
• Aluminium subframes for Volvo
S80 and V70 Cross Country
• Production time for one subframe,
6 minutes (capacity 1 subframe
per minute)
• 35 ABB robots
• Sand core handling, core knock-
out finishing, dimension control,
deburring waterjet cutting, x-ray
and shot blast unloading

ABB Flexible Automation

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Ford WAP, Windsor, Canada

• Castings for Ford engines

• 1 million cylinder blocks and heads
per year
• 94 IRB 6000 robots for assembly of
the moulds
• 9 IRB 8000 gantry robots for
handling of the fully assembled
moulds and castings

ABB Flexible Automation

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First Automotive Works / Daewoo,
Yangtai Peninsula, China

• Joint venture between Chinese

FAW and South Korean Daewoo
Group
• 1.4 l and 1.6 l GM engines
• Four Cold Box Core Shooting
Machines from Hottinger
• 3 ABB robots built for complete
core handling
• Capacity: 300 000 engine blocks
per year

ABB Flexible Automation

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Hillside Aluminium Smelter,
Richards Bay, South Africa

• Aluminium Ingot Production

• Largest robot installation in South
African Foundry Industry
• 15 ABB robots
• Dross-Skimming
• Stacking
• Bundle-Truck Loading

ABB Flexible Automation

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Benefits of Foundry Automation

• High quality and reduced scrap

rates
• Higher machine utilization and
higher up-time
• Increased manufacturing flexibility
and shorter set-up times
• Higher productivity and lower
manufacturing cost per part
• Improved working environment
• Labour cost reduction

ABB Flexible Automation

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