“How can I ensure that robots operate reliably in the harsh environment of a foundry without frequent breakdowns?” This is exactly the question many system planners, maintenance staff, and production managers in die casting manufacturing ask themselves. Because no matter how powerful modern robots are – in the foundry, they face extreme conditions that push even high-quality components to their limits.
This article explains the typical challenges encountered when using robots, why energy supply plays a central role, and how the right combination of dresspack and special cables can significantly reduce downtime.
Typical Stress Scenarios in Everyday Foundry Operations
Die casting is one of the most demanding industrial applications. Robots must work precisely and quickly to ensure the necessary cycle times. At the same time, cast parts have temperatures over 200 degrees Celsius when demolded, and the environment is filled with oil mist, emulsions, sand, and metal shavings—all of which are highly abrasive to all moving components. The energy supply system is particularly affected—this includes dresspacks, cables, and hoses that supply the robot with power, signals, and media. These components move constantly, are exposed to heat and abrasion, and often come into direct contact with hot parts or particles.
A look at two standard applications shows how quickly failures can occur with unsuitable components:
Entnahme des heißen Bauteils
After the mold opens, the robot grabs the freshly cast part. The cables on the gripper arm are in close proximity to the heat source. Without temperature-stable insulation, heat-resistant sheath materials, and protective hose systems, this can quickly lead to material embrittlement, melting, or cable breakage.
Cutting Off the Sprue and Riser
During this separation process, strong mechanical forces act on the system, and metal shavings and spray mist are generated. These attack unprotected cables both mechanically and chemically. Typical consequences include abraded cable sheaths, penetrating coolants, or clogged energy chains.
If you want to ensure long-term reliable operation, it’s not enough to rely solely on robust mechanics. The energy supply is often the weak point and therefore deserves special attention in selection, design, and protection.
Low-Wear Dresspacks with Robust Special Cables
Die LösunThe solution lies in a consistently application-specific energy supply. This includes:
- Highly flexible cables with abrasion-resistant, temperature- and chemical-resistant insulation
- Protective hoses with a smooth, heat-resistant surface
- Mechanical retraction systems to prevent uncontrolled cable and hose movement
For these challenges, Sumcab Robotics offers complete dresspack solutions specifically developed for demanding applications like die casting. As a subsidiary of Sumcab Specialcable in Spain, we draw on extensive cable expertise and combine it with strong experience in application-specific system integration.
Conclusion: Those Who Consider Energy Supply Secure Availability
Robots can operate reliably in die casting – if the energy supply is technically suited to the environment. With low-wear dresspacks, robust special cables, and well-thought-out routing, failures can be specifically avoided.
An optimally designed dresspack also offers ample room for cycle time optimization, as the right hose package allows more flexible movements than standard guidance.
Those who plan early and choose the right solution reduce maintenance efforts, prevent downtime, and increase productivity. Sumcab Robotics supports this with practical systems designed precisely for these conditions.