Case Study: Major U.S. Automotive Company - Foundry Industry

Business Challanges

High workman's comp rates and liabilities within the foundry industry create a need for a high level of factory automation. Plant manufactures engine block castings for General Motors at rates that require 24 hour plant operations, plant down time cannot be accepted.

Project Challanges

Tocco Feed conveyor must be capable of shuttling a 1200 lb sand casting in a gentle manner, less than 1G acceleration.
Unload end of the Tocco conveyor must lift and locate the sand casting 36” in under 7 seconds, in a close set down tolerance of 3mm.
As the engine block cools the casting can become physically bonded to the heat sink. This bonded unit must be separated at a force of 20,000 lbs.

The Results

BMH utilized a Bishop Wisecarver shuttle to move the sand casting into the Tocco machine for heat treatment. The Bishop Wisecarver shuttle handled the weight of the sand cast in a very smooth manner while moving 36 inches in 5.5 seconds.
Separator machines used a series of clamps and lift pins to force the engine block and heat sink separation at a force of 20,000 lbs.
All conveyor was designed with lubed for life bearings and components for limited maintenance. additional human resources to meet their business needs!