E-MOTOR HOUSING PRODUCTION

The sand cores are fed into the system either manually or fully automatically by robot. A robot then inserts the core package into the die. A casting robot designed for single and double casting transfers the prepared molten aluminum into the die, either with the gravity casting method by means of casting ladle or with the ROBOCAST V casting method.

Once the solidification time has expired and the die has been opened, the castings are ejected, removed by the removal robot, and fed to the next process (e.g., component cooling).

‌ROBOCAST

‌ROBOCAST V

‌TILTCASTER E

‌TILTCASTER S

‌DOUBLE CASTING PLACE

‌LINEAR CASTING LINE

The castings are transported fully automatically from the casting area to the component cooling area. Depending on customer requirements, the following variants are possible:

• Cooling rack with forced cooling
• Cooling conveyor with forced cooling
• Immersion cooling basin with water as cooling medium

As soon as the specified target temperature has been reached, the castings are transferred to the next process (e.g., premachining and decoring) by the handling robot.

‌COOLING RACK

‌COOLING BASIN

‌COOLVEYOR

Components

• Cooling rack
• Loading and removal robots on 7th axis

A handling robot or an alternative transport system feeds the cooled components into the premachining cell. A robot manipulates the castings into the hammering station, where the sand core is broken by pneumatic or hydraulic hammering tools. Now the components can be either embossed or inscribed by laser. This is followed by decoring of the components in one of the decoring systems.

The components are then premachined. In this process, risers and sprue are removed by different types of saw, and simple milling operations are also possible. Following optional abrasive blasting, the components are handed over for further machining.

‌CORECRACKER S

‌SPEEDLINER D

‌SPEEDLINER B

‌SWINGMASTER 315 EVO 3

‌SWINGMASTER 500

‌TWISTMASTER 400

‌TRIMMASTER PRESS

‌DECORING AND SAWING CELL

‌CORECRACKER B

Components

• Preliminary decoring unit (CORECRACKER S)
• Laser embossing station
• Sawing station
• Parts buffer
• Main decoring unit (CORECRACKER S & SWINGMASTER 315 EVO 3)
• Abrasive blasting unit
• Rotating/shaking station for component emptying
• Sand discharge unit
• Riser and chip discharge unit

The decored and premachined workpieces are fed fully automatically to the machining area. The SYNCROMILL machining centers can be loaded either by robot or portals. Once the components have been machined and processed to the defined extent, they are fed to the next process step.

‌SYNCROMILL C

Components

• SYNCROMILL C machining centers
• Loading and removal manipulators
• Chip discharge

The machined components are placed by robot directly into the test spaces of the leak testing system.

Testing can be conducted using various methods:

• Leak test
• Flow test
• Dynamic pressure test
• Pressure drop test
• Leak testing under water
• Tactile/optical measurements

‌CASTTESTER

Components

• CASTTESTER leak testing system
• Loading and removal robots

The machined components are fed fully automatically.

The following process steps can be performed:

• Cleaning and drying
• Computer tomography testing
• Presenting the components by robot for visual inspection by the operator
• Automatic palleting or packing
• Labeling

Components

• Cleaning cell
• Computer tomography system for component testing
• Robot test stations
• Component stacking unit
• Labeling station
• Strapping system
• Conveyor systems
• Automation