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Technology to improve health, safety and productivity:

Clansman Dynamics C620G Grinding Manipulator for Ariotti Foundry

Last year Italian Fonderie Ariotti SpA undertook a significant investment in technology, to improve safety, efficiency and respect for the environment. As part of the project, a Clansman Dynamics C620G grinding manipulator was installed. With 75kw of power in the spindle, this allows Ariotti to carry out the most demanding operations, faster and with improved operator safety.

The decision to opt for the C620G grinder was based not only on the well-known superior quality of Clansman Dynamics products but also on its functionality for very large castings and demanding grinding challenges. It has six axes of movement – vertical, horizontal, slew, yaw, pitch and roll. The grinding head is large, to allow it to transmit high power using a wide variety of grinding tools, such as an 815mm cutting disk as well as 600mm or 250mm grinding wheels. To maximise the utilisation, the grinder works in two different cells each one with its own table. The cells were designed by Clansman in direct collaboration with Ariotti; they are armoured for safety reasons and perfectly dedusted.

Variability of castings, manufacturing tolerances or small batch size, make automatic grinding complicated for castings heavier than 200kg. Clansman Dynamics foundry grinding machines combine the benefits of manual control with semi-automatic functionality to optimise metal removal rates and productivity, in ways that help the operator to work in a safer and more efficient way.

Semi-automatic functions include:

  • Pressure Control: For each ‘grinding wheel – metal’ combination, there is an optimum working pressure. Above it, the metal is over heated, and cracks can be produced; below it, the material is removed more slowly, and the operation is less efficient. The C620G control system ensures the grinding manipulator applies the pressure selected by the operator in a consistent way, relieving the operator of that element of his workload.
  • Geometric Control: The C620G control enables the operator to define working planes and ‘no-go’ areas. Following riser removal (e.g. using the Clansman Cannon) it is often desirable to grind off riser necks. With the C620G a plane can be defined for optimised material removal using pressure control, without worrying about going beyond what is necessary, because the grinder will not allow it. Geometric control allows the operator to set limits on the grinding area. This protects casting features from unintentional grinding.

Enhanced operator health and safety played a large part in the decision making process at Ariotti, where wellbeing of employees is paramount. With Clansman grinding manipulators, operators are separated from the physically demanding grinding mechanism and associated vibration, substantially reducing the risk of hand-arm vibration syndrome (sometimes abbreviated to HAVS and known as ‘white finger’).

Consistency and high productivity is also important. The power and control of the C620G is applied by the manipulator, so operators can be as productive in the last hour of the shift as in the first.

Clansman offers a wide range of manipulators, breakers, turntables and ancillary equipment for foundry and forge applications and provides automation, cell design and turnkey project services.

Ariotti provides a complete casting service and is at the forefront in the most demanding markets, offering casting, machining, Zeiss measure 3D control and quality assurance for components up to 70 tons. This year the leading Italian foundry celebrates its 110-year anniversary. This latest investment highlights a further commitment to the company’s employees and its neighbours.