4 AXIS AUTOMATIC TRANSFER SYSTEM

(AUTOMATION DESIGNER - SUZUKI, 2013)

Gravity die-casting machines operate at high temperatures, around 300° C. There are 8 such engine block casting machines at the Suzuki engine plant in Manesar, India. This automatic transfer system retrieves the hot casted engine block, thus preventing interaction between the operator and the hot casted part.

Client: Suzuki Casting Plant operators, Manesar, India

Team: 1 mechanical designer (design lead), 1 electrical engineer, 2 junior engineers, the installation team

Total Project time: 8 months | Design time: 3 months | Installation time: 15 days

USER STUDY

The users are the operators manning the GDC stations. Before the automation, the operators would stand beside the casting mold while the hot aluminum was poured in the mold and after to lift the casted engine block out of the mold with the help of a gripper suspended from above that was actuated with manual triggers. The engine block was transported to a sand breaking station where the operator would manually remove the sand core with a hammer, following which the part number would be engraved on the engine block and then the finished engine block would be placed on the storage cart. This process brought the operators in direct contact with the hot fumes rising from the casted hot engine block.

User: Gravity die casting Operators

User goals: Protection from heat generated by molten metal during casting process

My role: Mechanical designer

Tools used: Solid edge, Solid works, MSC Nastran

DESIGN OBJECTIVE

Upon observation and interviewing the operators the main concern identified was hot fumes inhaled by the operator. The two main solutions identified were personal protective equipment (PPE) like respirators and gloves for the operators or an alternative manufacturing process that doesn't require the operator being in close proximity of the molten metal and casted engine block.

DESIGN CONCEPT

A mechanical gripper that automatically transfers the engine block for the entire manufacturing process without the operator interacting with the hot engine block. It would pick up the casted hot engine block and place it on the sand breaking station where the sand core would be broken by automated hammers and the part number would be engraved and the gripper would automatically place the engine block in the storage cart.

MECHANICAL COMPONENTS

The gripper works on a four-bar claw mechanism actuated by a servo motor stepped down with a gear train. Rotation about the Z-axis is also controlled by a servo motor.

GRIPPER

Limit switches placed on the structure are used to gain feedback on the movement of the gripper. Two limit switches are placed on each end to cater for over-run and system failure.

LIMIT SWITCHES

The Y and Z axis of movement are driven on a rack and pinion mechanism while the X-axis of movement is driven by a revolving drive belt as it is moving a heavier load.

RACK AND PINION

DRIVE BELT

PRODUCT VIDEO

The automation solution was designed and installed on all 8 machines consecutively. The automation included bought components such as beams, channels, servo motors and limit switches, custom in-house machined components such as brackets and mounts and specialized custom components that were sourced from external machine shops around the country, such as gears, the gripper claws with polymer pads and channels.

Tanvi Designs