Automation of the final surface treatment of cast wheels

AUTOMATION OF THE FINAL SURFACE TREATMENT OF CAST WHEELS PRIOR TO THE PAINT SHOP

Name of contract:     Automated insertion of parts into customer trays
Term of delivery:       2016-2019

SPECIFICATION:

The project was implemented at the customer’s request for the automation of the PDV line (a total of 25 rows) for the final processing of aluminum cast wheels.

SOLUTION:

Line cycle of one row: 30 wheels / hour 
Capacity of one row: 51 types of wheels, 210 wheels / shift

DESCRIPTION OF THE AUTOMATED PROCESS:

• Automatic PDV grinders are used for grinding the wheels, currently there are 24 PDV lines in operation, which are included in the line together with the SR-5 machine. The last 25 rows are only with a PDV machine and without the special SR-5 machine. 
• The type of wheel is recognized by a camera system located behind the He-Li testers. The camera recognizes the aluminum disks and sends them to the appropriate PDV+SR-5 line. Each line is set up for one type of wheel. 
• The recognized wheels are transported by a roller conveyor system to the respective PDV line.

Basic characteristics of our solution:

The final removal of burrs and chips after casting and machining is done by PDV (outer surface of the wheel) and SR-5 (inner surface of the wheel) automatic grinding machines. These machines are designed for one type of wheel, and so where the production varies, there must be enough of these machines to cover as much of the production as possible. The conveyor system and cameras ensure the optimization of the production process with the smallest possible number of operators.