The customer is a foundry specialized in iron and steel casting, active in the production of heavy-duty structural components for sectors like energy, railways, shipbuilding, and heavy mechanical industry. They manufacture parts with complex geometries, and weighing up to 200 kg. Therefore, their treatment requires consistent, high-quality finishing.
The customer needed to automate the cutting and grinding processes for raw castings, which often have the following features:
irregular flash and burrs
variable thickness and shape
deformations after casting
Therefore, our system had to ensure the following:
Operational autonomy
Operator safety
Quality consistency all over the process and repeatability
Enough flexibility to handle different pieces
We delivered a turnkey robotic cell composed of the following: Rotary table system for fast loading/unloading to avoid downtimes and better automatize the whole process High-payload ABB robot (pieces up to 200 kg), configured to handle heavy parts with precision Interchangeable cutting and grinding tools equipped with the following:
Grinding wheels
Cup wheels
Pencil wheels
Cutting discs
Further custom tools based on casting requirements
Soundproof perimeter protection equipped with vacuum system and chip/dust containment system AI-based dynamic-compensation software able to:
Adjust toolpaths depending on the thickness, geometry, and deformation of the part to be machined
Maintain consistent quality throughout the process
Customize processes via pre-set recipes for each casting type
This solution is highly scalable and customizable, ideal for both variable small batches and serial production.
The customer noticed a significant increase in quality, efficiency, and safety. “We streamlined the process and minimized manual intervention. The robot adapts neatly to deformed parts or items with excessive burrs. This solution took us to the next level, both in terms of productivity and safety.”
Suprema S.r.l. | C.F. e P.IVA IT03390780983
Company Register entry number: BS - 530197
Share Capital: 10.000€
