WORKING IDEAS

KUKA ROBOTS FOR THE FOUNDRY AND FORGING INDUSTRY

DIE CASTING GRAVITY CASTING PERMANENT MOLD CASTING LOW-PRESSURE DIE CASTING SAND CASTING FORGING

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KUKA offers a wide range of shelf-mounted and heavy-duty robots that can

be mounted either on the floor or on the ceiling, making them the most

multifunctional and flexible foundry robots on the market. KUKA robots can

contribute to rationalizing cost-effective automation solutions in all areas of

the foundry and forging industry. Whatever the application, be it loading

and unloading of die-casting machines, deflashing presses or machining

centers; spraying; finishing processes, such as milling, sawing and grin-

ding, or handling hot, heavy forgings: KUKA will supply just the right robot

to meet your every need – even for applications in harsh ambient conditi-

ons. The high quality and availability of KUKA robots will significantly boost

your productivity.

Loading and unloading

Safe and rapid unloading of both small parts

and complex castings from a die-casting

machine.

KUKA robots can, of course, also carry out

the precise loading and unloading of finish-

ing centers, deflashing presses, forging ham-

mers and drop forges.

ESCALATORSCYLINDER HEADSALUMINUM WHEEL RIMSENGINE BLOCKSAutomotive plants, steelworks, foundries, forges. With its diversity of ro-

bot types, KUKA has established itself in the wide-ranging foundry market.

Even lighter, even more flexible, even more compact – and specially adap-

ted to the needs of die casting, permanent mold casting, sand casting and

forging processes KUKA – robots offer you the right solution for any task

and any application.

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KUKA ROBOTS FOR EVERY EVENTUALITY

Finishing work

Precise removal of sprue and flash. The stiff-

ness of KUKA robots allows accurate sawing

and milling along precisely defined paths.

KUKA robots grind and polish castings and

sand cores with the utmost precision.

Handling

Assembly and handling of sand core parts.

Neither the assembly of delicate core parts

nor the handling of complex cores poses

problems for a KUKA robot.

Spraying of parting agent

Precise contour spraying results in the opti-

mized thermal economy of the die, ensuring

high quality castings which can also lower

cost due to reduced parting agent consump-

tion and the use of simpler dies.

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6-axis robots give you the decisive edge

6-axis robots offer many advantages over conventional gantry systems in a wide range of applications: they have a longer

life cycle, require less maintenance and ensure a quicker return on investment. Their great flexibility and mobility in 3D space

allow for the handling of both complex and delicate work pieces and the effective utilization of non-productive time.

The advantages of standard KUKA robots...

➔ Compact robot arm

➔ Small footprint

➔ Low weight of robot

➔ Payload capacities from 16 to 570 kg

➔ Greater work envelope depth, both forwards and upwards

➔ PC-based controller

… and shelf-mounted robots…

➔ Low height

➔ Robot “knee” moved forward and downward

➔ Greater work envelope depth, both forwards and downwards

… and the benefits for you

➔ Ideal combination of high payload capacity and small footprint

➔ Fast and reliable – even for complex tasks

➔ Availability: nearly 100 %

➔ Optimized cycle times

➔ Process reliability

➔ Assured productivity

➔ Easy integration of peripheral devices,

e.g. deflashing presses, end of arm tooling

➔ Flexible range of applications

➔ Compact cell layout

PRODUCTIVE MODULARTIME-SAVINGEFFICIENTVERSATILE

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The variety of KUKA Robot applications can be extended still further using a KUKA linear unit. This can be installed on the

ceiling, floor, or on a gantry, according to your specific requirements. The result is maximum mobility and functionality for

your KUKA robots. This covered linear traversing axis, specially designed for use in foundries and forges, is safe to walk on,

and provides optimum protection against fouling of the mechanical system and the energy and fluid supply system by alu-

minum spatter, molten material or sand, and plays a major role in ensuring the process reliability and availability of your

system.

THE 3D ADVANTAGE

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On the die-casting machine

KUKA shelf-mounted robots can be installed

on top of die-casting and injection molding

machines or machine tools to save space, thus

allowing compact system concepts.

Positioning the robot on top of the machine

leaves the machine highly accessible and al-

lows time-saving unloading processes to be

carried out with the safety gates closed.

You can exploit the flexibility of the robot for

cooling tasks or parting agent applications.

This ensures an accurate and finely-dosed

spraying process, particularly in the case of

complex dies.

➔ Space-saving

➔ High availability

➔ Flexibility

➔ Short unloading times

➔ Unloading possible with safety gate closed

Next to the die-casting machine

Installation of the unloading robot from the

non-operator side of machine allows a process-

optimized cell layout.

In the next to the machine mounting position,

non-productive time can be used effectively for

machining, significantly boosting productivity.

The key to this is the flexibility and mobility of

the compact, 6-axis KUKA robot, whose work

envelope can optionally be extended by means

of an additional linear unit.

➔ Compact cell layout

➔ Flexible installation position

➔ Optimal utilization of non-productive times

➔ Automation of existing system possible

➔ Good accessibility

Inverted installation in front of die-

casting machine

The suspended installation of the KUKA robot

in front of, next to or above the machine al-

lows even more flexible system concepts.

The advantage of this kind of installation is

the optimal utilization of space and non-pro-

ductive times, and the high availability that

can be attained by 6-axis robots, even in the

automation of large machines.

This position is particularly suitable for com-

pact new installations and for subsequent

automation of existing system concepts.

➔ Compact and flexible cell concepts

➔ Ideal utilization of non-productive times

➔ Process reliability

➔ Large to very large clamping force ranges

➔ Good accessibility

KUKA robots work perfically in any position. Depending on the specific requirements with respect to the position of the

die-casting die, trajectories, accessibility, safety and space, KUKA robots can be installed on, next to or above the ma-

chine.

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NOTHING IS IMPOSSIBLE

Die casting

KUKA robots have established themselves in the

die-casting industry by optimally combining payload

capacity and space requirement. Their flexible appli-

cation potential, either by or on the die-casting ma-

chine, standing or inverted, makes a custo mized and

compact cell layout possible.

Forging

KUKA robots with Foundry equipment are particularly

suitable for use in forges, as they maintain consis-

tently high performance even at high temperatures

and in dirty environments.

Sand casting

The assembly of sand cores in a core assembly line

places high demands on the robot with respect to pay-

load capacity, reach and precision.

The KUKA PC controller allows the use of flexible end

of arm tooling systems whose drives can be program-

med as additional external axes. This means that it

is possible to pick up a wide range of different core

types without the need to change gripper.

Gravity and low-pressure die casting

KUKA robots enable precise and repeatable pouring of

the melting charge into permanent molds, sand cas t -

ing molds or low-pressure die-casting systems.

The range of possible applications for KUKA robots knows practically no bounds. A KUKA robot can take on a wide range of

tasks in the overall foundry process. This is because the industry-specific KUKA Foundry equipment make it possible to use

KUKA robots even in the toughest environments.

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Work envelope A (mm) B (mm) C (mm) D (mm) E (mm) F (mm) G (mm) Volume (m3)

KR 60 L30-3 KS-F 2.330 4.130 2.628 1.445 1.183 900 1.22 0 47,9

KR 60 L30-3 F 2.894 3.795 2.429 1.445 983 1.480 1.220 47,8

FLEXIBLE FAR-REACHINGPOWERFUL CUSTOM-TAILORED DIVERSE KUKA offers you the largest product range of shelf-mounted robots, with a wide variety of reaches and work envelopes.

They can be adapted to their surroundings through the use of optional arm extensions or KUKA traversing units. The pa-

yload capacities of robots manufactured especially for use in foundries and forges range from 16 to 210 kg.

Both KUKA shelf-mounted robots and KUKA standard robots have large work envelopes. The aim of the new design of

the KUKA shelf-mounted robots was not merely to obtain a long reach forwards and upwards, but also to achieve the

maximum possible reach forwards and downwards. This was delivered as a result of the low overall robot height and the

forward shifting of the robot knee.

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Standard robots:

– Protection rating IP 65

➔ Dust-proof

➔ Protected against waterjets

Foundry equipment for KUKA robots:

– Complete robot painted with triple coat of

two-component paint

➔ Particularly impact-resistant and hard-wearing,

resistant against both acids and alkalis

– Wrist axes:

– Protection rating IP 67

➔ Dust-proof

➔ Protected against damage from short-time

submersion in water

➔ Corrosion-resistant materials

➔ Additional seals and adhesive

➔ Heat-resistant and heat-reflecting special

paint finish

– Included in the standard package:

Pressure regulator which prevents the

penetration of water or dust by generating

an overpressure in the arm housing

KUKA SHELF-MOUNTED ROBOTS

Configuration example based on a KR 60 L30-3 KS-F shelf-mounted

robot

Arm extension (200 or 400 mm)

In-line wrist with arm extension,

protection rating IP 67, Foundry version

Up to 2628 mm reach

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The advantage of KUKA shelf-mounted robots is their modular construction which begins during their manufacture: not only

can KUKA robots be used in a wide range of industries and applications, they can also be custom-adapted to any situation

– by means of arm extensions or linear units. The advantages: high availability, small number of components, and short de-

livery times.

As well as the in-line wrist, the arm extensions also have a special paint finish (a triple coating of two-component paint with a

high final hardness that is impact-resistant and hard-wearing, resistant against both acids and alkalis). The interface between

the in-line wrist and the arm extension is fitted with additional seals.

Interfaces Controller Robots

MODULARITY FOR ADDED VALUE –KUKA SHELF-MOUNTED ROBOTS ARE FLEX

Medium payloads

High payloads

Additional options,e.g.

HMI Studio, KUKA.PLC

Energy supply

systems

Energy supply unit

on axis 3

External periphery, e.g. linear

robots, assembly stations

KUKA KCP

KUKA KR C2

Low payloads

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Reach Horizontal 1.801 mm Vertical 1.105 mm Module Wrist

Payload 16 kg KR 16 KS-F

Reach Horizontal 2.233 mm 2.433 mm 2.628 mm Vertical 1.402 mm 1.600 mm 1.800 mmModule Wrist Arm extension Arm extension 200 mm 400 mm

Payload 30 kg KR 30-3 KS-F KR 60 L30-3 KS-F 45 kg KR 60 L45-3 KS-F 60 kg KR 60-3 KS-F

Modular components Machines

XIBLE IN THEIR RANGE OF APPLICATIONS

Recommended

for die-casting

machines up to

500 t

Recommended

for die-casting

machines up to

1,200 t

Recommended

for die-casting

machines over

1,200 t

Reach Horizontal 3.100 mm 3.300 mm 3.500 mm 3.700 mm 3.900 mm Vertical 1.575 mm 1.775 mm 1.975 mm 2.175 mm 2.375 mmModule Wrist Arm extension Arm extension Arm extension Arm extension 200 mm 400 mm 600 mm 800 mm

Payload 100 kg KR 180 L100-2 K-F KR 210 L100-2 K-F 110 kg KR 150 L110-2 K-F 130 kg KR 150 L130-2 K-F KR 180 L130-2 K-F 150 kg KR 150-2 K-F KR 180 L150-2 K-F KR 210 L150-2 K-F 180 kg KR 180-2 K-F KR 210 L180-2 K-F 210 kg KR 210-2 K-F

KUKA energy supply units can optionally be supplied for installation on axis 3. They are available in a choice of variants:

Profibus DP, Interbus and CAN DeviceNet.

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What applies to our shelf-mounted robots is just as true on the floor: whatever the nature of your application, whatever task

your robot has to perform, and whatever the ambient conditions – our robots’ modular design guarantees you the optimal

solution. The KUKA KR C2 controller makes it possible to implement complete manufacturing processes, including the most

varied of tasks, through the use of an integrated control concept.

Interfaces Controller Robots

SUPERIOR ON THE FLOOR, TOO –KUKA ROBOTS ARE FLEXIBLE IN ANY POSI

Low payloads

Medium payloads

External periphery, e.g. linear

robots, assembly stations

KUKA KCP

KUKA KR C2

High payloads

Heavy payloads

Energy supply unit

on axis 3

Energy supply

systems

Additional options, e.g.

HMI Studio, KUKA.PLC

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Reach Horizontal 1.611 mm Module Wrist

Payload 16 kg KR 16 F

Reach Horizontal 2.033 mm 3.102 mm 2.230 mm 2.429 mm Module Wrist Wrist Arm extension Arm extension 200 mm 400 mm

Payload 16 kg KR 30 L16 F 30 kg KR 30-3 F KR 60 L30-3 F 45 kg KR 60 L45-3 F 60 kg KR 60-3 F

Modular components Machines

ITION

Recommended

for die-casting

machines up to

500 t

Recommended

for die-casting

machines up to

1,200 t

Reach Series 2000 2.700 mm 2.900 mm 3.100 mmModule Wrist Arm extension 200 mm Arm extension 400 mm

Payload 110 kg KR 150 L110-2 F 130 kg KR 150 L130-2 F KR 180 L130-2 F 150 kg KR 150-2 F KR 180 L150-2 F KR 210 L150-2 F 180 kg KR 180-2 F KR 210 L180-2 F KR 240 L180-2 F 210 kg KR 210-2 F KR 240 L210-2 F 240 kg KR 240-2 F

Recommended

for die-casting

machines up to

4,500 t

Recommended

for die-casting

machines up to

3,000 t

Reach 2.826 mm 3.076 mm 3.326 mmModule Wrist Arm extension 250 mm Arm extension 500 mm

Payload 240 kg KR 360 L240 F 280 kg KR 360 L280 F 340 kg KR 500 L340 F 360 kg KR 360 F 420 kg KR 500 L420 F 500 kg KR 500 F

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KUKA control technology makes operator control of your robot easy. Integration into higher-level control structures is no pro-

blem. Special offline and simulation programs shorten start-up times and help you to optimize your custom programming.

PROGRAM CONSULT CONTROL SIMULATE TRAIN SUPPORT

Offline programming

with KR C Office

With KR C Office, you can pro-

gram your entire process off-

line. The advantages: pro duction

can continue un interrupted.

Con version time is minimized.

Newly created programs can be

used without modification.

Simulating applications

with KUKA Sim

With KUKA Sim you can create

a simulation of your entire ap-

plication. This enables system

concepts, processes, cycle

times, reaches, collision checks

and offline programming to be

tested in a targeted manner

and, if required, optimized be-

fore commissioning.

Simple operator control

with the KUKA KCP

The KCP combines simple

operator control with rapid

programming: template forms

and simple menu-guided pro-

gramming make it easy to in-

put commands; the 6D mouse

can be used to move the indi-

vidual robot axes intuitively

and to save the corresponding

coordinates directly.

Easy programming with

the KUKA KR C

The robot controller can be

programmed easily thanks to

its Microsoft Windows inter-

face. It is expan dable, can be

integrated into networks via a

bus, and contains ready-made

software packages – impor-

tant factors for the automa-

tion of the future.

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Customer Support

In addition to custom-tailored robot systems, spare parts, robot rentals and used robots, KUKA also offers you a wide range

of services: from planning to commissioning and production – our employees support you during every phase of your project.

And our worldwide, modularly structured seminar program imparts valuable expertise – and can also provide robot cells for

training at your location.

The KUKA partner network

KUKA works together with selected specialists in various industries to implement the optimal

solution for you. These system integrators are brought together in the KUKA partner network. Our

close cooperation with industry specialists, die-casting machine manufacturers, system partners

and innovative end customers is one of the cornerstones of KUKA’s success – and a constant

challenge to optimize our solutions still further. Thanks to this expertise in creating custom solu-

tions, and a dense network of regional training and service centers, KUKA has earned an outstan-

ding reputation in the foundry and forging industry.

Planning

Customized user interfaces, application soft-

ware, offline programming, simulation, cycle

time analyses, feasibility studies – even in the

planning phase KUKA will provide you with

whatever you need to ensure that your system

will operate smoothly.

Production

Programming, optimization, immediate assis-

tance – with KUKA, the availability of your

systems is in the best of hands. Let us prove

it: with remote diagnosis, on-site servicing,

updates and upgrades, customized mainte-

nance agreements, spare and used parts, and

cutting-edge logistics…

Commissioning

We optimally integrate custom software mo-

dules, sensors, vision systems and robot tools,

carry out load analyses while the program is

running, and give you advice, support and in-

struction during the commissioning process

– all to help ensure that your system is cost-

effective to operate right from the outset.

END CUSTOMER

IN

TEGRATOR M

ANUFACTURER KUKA ROBOT

ER

www.kuka.com

CONTACTINFOADDRESSES No

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KUKA Robotics Corp.22500 Key DriveClinton TownshipMichigan 48036United States of AmericaTel. +1 586 7959090Toll free: 866 8735852Fax +1 586 5692087info@kukarobotics.com

KUKA offers a comprehensive range of products, with optimal solutions for every requirement and every industry.

What can KUKA do for you?

Low Medium High Heavy Special

payloads payloads payloads payloads models

from 3 to 16 kg from 30 to 60 kg from 100 to 240 kg from 360 to 570 kg Shelf-mounted robots

Palletizing robots

Press-to-press robots

KUKA international:Argentina, Australia, Austria,Belgium, Brazil, Chile, China,France, Germany, Hungary,Italy, Korea, Malaysia, Mexico,Norway, Portugal, South Africa,Spain, Sweden, Switzerland,

Taiwan, Thailand, UK, USA