Robots are worked in die casting through high-precision robotic arms, specialized end effectors, and deep integration with die-casting machines.
What is a die-casting robot? The Die-Casting Robot represents a class of industrial robots whose focus is on the die-casting of metal. Their primary purpose is to automate die-casting to the extent it is possible so that production efficiency is maximum, costs are minimum, and quality is consistent. They are extensively used in the metal die-casting production lines in the automotive, electronics, home appliances, etc. Industries.
Robots are widely used in die casting due to their ability to handle high temperatures, hazardous materials, and repetitive tasks with precision and consistency. The use of robots in the die casting process not only improves productivity and product quality, but also significantly improves the safety and comfort of the working environment.
This article first introduces the main functions of robots. Then it explains different Types of Die Casting Robots . Next, it covers the benefits of using die casting machine with robots Finally, a case study of how our Haichen robot automation helps customers improve efficiency and safety.
Main Function of Robots work in Die Casting
Robots work in die casting mainly do below four function. Each one directly affects cycle time and product quality.
Automatic Part Removal
- After the mold opens, the robot quickly enters the mold area and grips the casting
- Transfers the casting to a cooling tank, trim press, or conveyor
- Removal time usually 3-8 seconds, 30-50% faster than manual
- Custom grippers suit different shapes, grip force adjustable
Mold Spraying
- The robot holds a spray gun to apply release agent evenly
- Spray path, time, and flow can be programmed
- Blows air first to clean, then sprays for cleaning and cooling
- Even spray uses less agent and extends mold life
Automatic Ladling
- The robot holds a ladle to scoop metal from the furnace
- Controls pour angle and speed for smooth flow
- Syncs with the machine, pours after mold closes
- Reduces splash and oxidation, improves accuracy
Trimming and Post-Processing
- The robot places the casting accurately into a trim press
- Can also do deburring and grinding
- Multi-station robots do several jobs in one cycle
- Less handling, lower risk of damage
Different Types of Die Casting Robots
When in die casting, robots work need a complete system. Different robot types suit different conditions.
Six-Axis Articulated Robots
- Six movement axes, very flexible, like a human arm
- Load capacity 5-50kg, repeat accuracy ±0.05-0.1mm
- Reach 800-2500mm, fits different machine sizes
- Good for complex molds, deep cavities, and multi-station work
Four-Axis Palletizing Robots
- Simple structure, fast movement, good for flat transportation
- Load capacity 10-200kg, repeat accuracy ±0.1-0.2mm
- Good for large part handling and simple pick-and-place
- Costs less than six-axis, good for standard production
Linear Coordinate Manipulators
- Moves in X, Y, Z straight lines, simple and reliable
- Load capacity 2-50kg, repeat accuracy ±0.1-0.2mm
- Good for fixed removal paths in mass production
- Low maintenance, but less flexible
Collaborative Robots
- Have force sensing and collision detection, no safety fence needed
- Load capacity 3-15kg, repeat accuracy ±0.05-0.1mm
- Good for working close with people
- Used for precision assembly and final inspection
Preparation of Molds
- Application of Lubricant
- Regulating the Temperature of the Die
Application of Lubricant
Robots have the ability to apply mold release agents or lubricants to the die cavity. This achieves more uniform application, which is important for adequate release and surface quality of the casting, for example Yaskawa MH24 can have sprayers mounted on it to lubricate the mold cavities uniformly.
Regulating the Temperature of the Die
Some robots have been customized to fit with die temperature control or monitoring sensors to maintain optimal casting conditions.
Automatic Handling of Materials
Robots have developed the capability of performing an extensive range of material handling functions in the die casting operations such as:
- Automated pouring of molten metal
- Working with inserted molds
- Post-cleaning and post-cooling operations
Automated pouring of molten metal
The robot is capable of steady pouring of molten metal into the mold without any sudden movements that are often witnessed in manual operations.
Working with inserted molds
Robots are capable of rapidly and accurately inserting and removing molds within a die casting machine which reduces cycle time and improves efficiency.
Post-cleaning and post-cooling operations
The robot achieves the removal of solidified castings out of the mold and transfers the castings to the cooling stations or to other processing sections that are queued to work on the castings.
Benefits of using a die-casting robot
Using die casting robots has numerous advantages especially in productivity margin, product quality, safety and cost control.
- Improve productivity and stability
- Reduce of labor costs
- Enhanced Security
Improve productivity and stability
- Die casting robots can work round the clock, only stopping for equipment maintenance and repair.
- Such uninterrupted working schedule considerably increases productivity.
- Moreover, uniterruptibility of robot’s operations leads to more standard and repeatable production processes which greatly diminish the probability of errors.
Reduce labor costs
- As costs of labor increase, the level of automation that is economically viable also increases.
- For instance, in China, although die-casting workers are paid higher salaries, the payback period for robots is typically within a year.
Enhanced Security
- Die casting environments often involve hazards such as high temperatures, dust and noise.
- And robots can protect workers from injury by replacing manual labor for high-risk tasks such as removing hot castings from molds.
- In addition, robots can reduce the amount of time workers are exposed to high temperatures, reducing the risk of occupational disease.
HAICHEN Practice Of Die Casting Machine robots
HAICHEN Machinery provides not only high-performance die casting machines but also expert robot system integration. The core value is the deep synergy between the host machine and the robot. This ensures robots work in die casting at their best.
Background
An aluminum parts maker had a capacity bottleneck and safety compliance pressure.
Their old line used manual extraction and spraying. Each shift needed four operators. Parts were often damaged during handling, and uneven spray caused defects. The high-heat work area also had safety risks.
HAICHEN Robot Integration Selling Points
- Deeply Integrated Control System: HAICHEN’s die casting machine PLC and the robot controller share data and sync in milliseconds. The robot’s extraction and spray actions are triggered directly by the machine’s mold-open signal. No external relays or separate timers are needed. This one-system control removes communication delays. Pick position error is under 0.2mm every cycle.
- Machine Design Made for Automation: HAICHEN die casting machines have standard robot mounting interfaces, safety interlock signals, and enough free space built into the design. The ejector position and force are coordinated with the robot’s grip path. This ensures the casting is in the best spot for the robot to pick.
- Stable Process is the Foundation: HAICHEN machines provide steady clamping force and repeatable injection profiles. This means every casting has the same quality, mold open position, and ejector stroke. This stability is what allows the robot to work with a fixed program and pick parts reliably every time.
- Complete Automation Cell Delivery: HAICHEN does not just supply robots. They deliver the full cell: die casting machine, extraction robot, spraying robot, trim press, and conveyor. The HAICHEN team handles the layout, cycle programming, tuning, and operator training. The customer gets a “plug and play” production unit.
Key factors of select a die-casting robot
When choosing a die-casting robot, several key considerations must be taken into account to ensure the robot meets the specific needs of your production process. Here are the main factors to consider:
- Selection of robot type
- Production requirements and machine performance
- Work environment and mission requirements
- Speed and Cycle Time
Selection of robot type
There are several types of die casting robots, including flexible articulated robots such as SCARA robots and six-axis robots.
Articulated robots are suitable for fast, precise movements, while six-axis robots are suitable for complex tasks such as disassembly and assembly of parts. Choosing the right type of robot for your specific needs is key.
Production requirements and machine performance
Production size and product complexity directly affect machine selection. For example, a high-volume production line may require faster cycle times and greater load capacity, while the production of complex parts requires greater precision and flexibility.
Work environment and mission requirements
Before selecting a robot, it is important to identify the specific tasks it will perform in a die casting line, such as whether it will be handling hot metal, cleaning burrs or performing part handling. This helps determine the robot’s load capacity, its operating range, and whether special features are needed.
Speed and Cycle Time
The robot’s speed should match the cycle time of the die-casting process to avoid bottlenecks. Robotic simulation can help validate cycle times and ensure the robot can keep up with production rates.
Die casting machine supplier: Haichen Machinery
Haichen is a die casting machine factory located in Ningbo, China, mainly supplying cold chamber die casting machine and hot chamber die casting machine. Besides machines, we also supply die casting auxiliary equipments and spear parts, including robots, conveyor, spray systems, mold temperature controllers, and industrial robots.
If there is any demand, welcome to consult us.
