New requirements demand innovative solutions

Fill has developed a vacuum metering system in the form of the ROBOCAST V, which revolutionizes the casting process for new types of drive system. 

The ROBOCAST V from Fill ensures maximum casting quality while reducing the amount of return scrap material. The innovative casting system is used for low-oxide collection, manipulation, and metering of molten aluminum. Consistent, reproducible casting parameters are decisive factors for ensuring constant casting quality. This is now a reality with the development of the ROBOCAST V. The world premiere will take place at the leading international trade fair for die casting, Euroguss 2022, which will be held in Nuremberg in June 2022.

Gurten, January 11, 2022 – A rapid transition to alternative drive concepts is taking place in the field of mobility. Existing casting systems are often only suitable to a limited extent for producing the new types of drive component. "The challenge for the automotive industry and machine builders is to develop and implement completely new manufacturing concepts. With the ROBOCAST V, we have succeeded in taking a decisive step forwards," reports Thomas Rathner, Head of the Casting Technology Competence Center at Fill.


Dynamic, precise, reproducible
Molten metal is metered dynamically in the new ROBOCAST V. This enables delivery rates of 0.5 to 2.7 kilograms per second. And the delivery rate is varied and adapted automatically during pouring to comply with the requirements of the die. The delivery process can be parameterized such that the mold is always filled from below the molten metal level after casting starts. Oxide formation in the system is prevented by permanent application of a protective atmosphere to the molten metal.

Seamless data acquisition and storage
The CYBERNETICS PRODUCE software tool integrated in the ROBOCAST V casting system ensures seamless recording and storage of all the relevant process parameters. This enables efficient and reliable component traceability. CYBERNETICS PRODUCE allows foundries to analyze reproducible processes and optimize the procedures accordingly using key performance indicators.

Simple operation and easy to maintain
The ROBOCAST V also scores highly with simple handling, clear user guidance, and clearly arranged, "grippy" controls. The system is extremely easy to maintain. All wearing parts can be easily replaced without great effort in a special service unit as and when required.

Corporate data
Fill is a leading international machine engineering company based in Gurten, Upper Austria. With sophisticated high-tech systems and custom manufacturing solutions for metal, plastics and wood, Fill makes its customers the best in their fields. The automotive, aviation, sports and building industries all benefit from Fill’s expertise. Since it was founded in 1966, the company has distinguished itself through enormous innovative strength, strong values and the best jobs. “If you are seeking the best solution, shape your future with Fill” is the guiding principle of the company’s more than 950 employees. “Wir sind 1! We are one!” is their vision and stands for togetherness not only with the team, but also with customers, suppliers and partners. The company is 100 percent family-owned and is managed by Andreas Fill (CEO), Martin Reiter (CSO), Alois Wiesinger (CTO) and Günter Redhammer (COO). In 2020, Fill recorded sales of around 144 million euros.

Legend: Vacuum metering fixture: Fill has developed the ROBOCAST V vacuum metering system specifically for casting new types of drive components.
ROBOCAST V casting system: The ROBOCAST V guarantees maximum casting quality while reducing the amount of return scrap material.

Photos: Fill Maschinenbau (free)


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