At the heart of industrial transformation, the foundry sector is experiencing an era of unprecedented innovation thanks to the introduction of robotics and automation.

From casting to post-casting processing, these technologies are revolutionising traditional processes such as grinding, cutting and deburring, improving the quality of finished products and providing greater safety for operators.

Let’s discover together how these robotic systems are redefining the future of the foundry.

Grinding: efficiency and precision within the reach of robots

In the foundry industry, grinding is a crucial operation for achieving uniform, high-quality surfaces. The use of specialised robots in grinding processes enables continuous operation, bringing considerable advantages:

• Automation and speed: robots operate continuously, increasing productivity and reducing processing times.
• Constant accuracy: thanks to the elimination of human errors, each workpiece receives a uniform finish, regardless of production volume.
• Flexibility: robotic systems easily adapt to different geometries, without the need for complex structural interventions.

Furthermore, the adoption of advanced technologies – such as sensors and real-time feedback systems – allows robots to adjust the speed and pressure applied, optimising the process according to material and surface specifications.

Cutting: precision and savings with automation

In industrial cutting operations, the introduction of robotics and computer numerical control (CNC) machines have also brought many benefits:

• Precise cutting: complex operations are performed to very tight tolerances, eliminating the need for corrective interventions.
• Waste reduction: automation minimises errors, optimising the use of materials and significantly reducing waste.
• Machining of difficult materials: ideal for hard alloys and high-strength materials, robotic cutting ensures precise and reliable machining.

For flawless results, innovative systems such as automated laser or plasma cutting are employed, ensuring high performance even with particularly thick or hard materials and helping to extend tool life.

Deburring: safety and quality in the service of automation

Deburring, traditionally a delicate operation, has benefited greatly from automation. Deburring robots offer significant advantages:

• Precise deburring removal: equipped with abrasive tools or rotating brushes, robots remove burrs uniformly, preserving the integrity of the workpiece.
• Increased safety: automation reduces operators’ exposure to physical hazards such as cuts or accidents, significantly improving working conditions.
• Operational efficiency: automated deburring is faster than manual machining, making the process ideal for large-scale production.

Advanced techniques, such as vibratory deburring or the continuous use of rotating tools, are integrated into these processes, adapting perfectly to the specifications of each part and guaranteeing high quality results.

The overall benefits of robotics in the foundry

The integration of robotics and automation into production processes brings benefits that extend throughout the entire production cycle. Uninterrupted machining reduces cycle times and increases overall production capacity, while lower labour costs and optimised operational efficiency make the investment in robotics highly profitable. In addition, real-time monitoring allows quality parameters to be kept constant, reducing rejects and discrepancies between production batches. The ability to quickly re-programme robots makes it possible to deal with different types of parts, reducing downtime and improving production dynamics, while also contributing to a more sustainable use of resources.

Foundry 4.0: innovation that marks the future

The evolution towards ‘Foundry 4.0’ integrates robotics with advanced technologies such as Artificial Intelligence, the Internet of Things (IoT) and data analysis, creating a manufacturing ecosystem where continuous monitoring and predictive maintenance become everyday realities. These intelligent systems optimise operating parameters and predict possible failures, ensuring greater reliability.

Communication between automated machines promotes a dynamic and optimised workflow, capable of adapting quickly to changes in production, while the introduction of collaborative robots (cobots) allows operators to work side by side with technology, combining the precision of automation with human flexibility.

Conclusion: robotics, a pillar of the foundry of the future

Robotics and automation are charting an innovative course in the foundry industry, transforming traditional operations into highly efficient, precise and safe processes. The technologies used in grinding, cutting and deburring not only raise the quality of finished products, but also enable significant cost reductions and a more sustainable use of resources.

In an era that is increasingly looking towards Foundry 4.0, the integration of advanced solutions represents the future of manufacturing. Efficiency, safety and sustainability come together to create manufacturing processes of excellence, and Arcos is ready to accompany companies on this journey towards innovation.

Find out more about Arcos’ innovative solutions by visiting our website.