Deburring casting parts presents significant challenges due to variability in excess material geometry and harsh production environments. At Heidenreich & Harbeck, where precision casting parts weighing up to 16 tons are manufactured, manual deburring exposed workers to extreme temperatures, airborne particulates, and repetitive strain injuries. Our collaboration with Boll Automation yielded a breakthrough solution: integrating KUKA KR QUANTEC series robots equipped with adaptive tooling and sensor systems. This system achieves complete automation of post-processing for diverse casting parts, regardless of burr complexity.
The core innovation lies in the KUKA KR 120 R2900 F extra robot’s 6-axis articulation and reverse-testing technology, which identifies burr profiles through integrated sensors. Force dynamics during material removal are calculated using:
$$F_d = \mu \cdot N + k \cdot A \cdot v^2$$
Where \(F_d\) is deburring force, \(\mu\) is friction coefficient, \(N\) is normal force, \(k\) is material resistance, \(A\) is contact area, and \(v\) is tool velocity. This enables precision material removal without damaging underlying casting parts structures.
| KUKA KR QUANTEC Series Specifications | Range |
|---|---|
| Payload Capacity | 90–300 kg |
| Reach | 2500–3900 mm |
| Maintenance Interval | 20,000 operating hours |
| Temperature Resistance | Up to 120°C continuous |
Foundry-optimized features include heat-resistant steel tooling with aluminum-white coatings and positive-pressure enclosures preventing dust ingress. Cycle efficiency gains are quantified by:
$$\eta = \frac{T_m}{T_a} \times 100\%$$
Where \(\eta\) is efficiency gain, \(T_m\) is manual process time, and \(T_a\) is automated cycle time. For complex casting parts, \(\eta\) consistently exceeds 220%.
| Performance Metric | Manual | Automated |
|---|---|---|
| Deburring Consistency | ±1.5 mm | ±0.05 mm |
| Tool Wear Rate | High | Reduced 40% |
| Reproducibility | Operator-dependent | 99.7% |
Integrating a 750 kg 3-axis positioner enables omnidirectional access to casting parts. The system’s flexibility handles part geometries from 0.5–16 tons. Dynamic path optimization minimizes non-value-added motion through:
$$P_o = \frac{\sum (L_{opt})}{\sum (L_{path})} \times 100\%$$
Where \(P_o\) is path optimization efficiency, \(L_{opt}\) is optimal toolpath length, and \(L_{path}\) is actual trajectory. Typical \(P_o\) values exceed 92% for irregular casting parts.
Global manufacturing shifts underscore this technology’s relevance. With 150,000+ industrial robots deployed worldwide, KUKA supports casting parts production across automotive, aerospace, and heavy equipment sectors. The 2015 RoboCup’s standardization on KUKA youBot platforms further validated our architectural robustness for extreme-condition applications.
Post-implementation data from Heidenreich & Harbeck confirms 31% higher throughput, 18% lower tooling costs, and eliminated OSHA-reportable incidents. As casting parts grow in complexity, adaptive robotic deburring becomes indispensable for maintaining dimensional tolerances below 0.1 mm while ensuring human-operator safety.