Robot Arm Maintenance for Ford Foundry

During my undergraduate studies focused on production technologies and robotics, I had the opportunity to work on optimizing industrial robot arms in automotive manufacturing environments. Industrial robots have been the backbone of modern manufacturing for decades, but they face significant challenges in harsh environments like foundries. My work at Ford’s Cologne-Niehl facility provided valuable insights into maintaining and improving robotic systems in demanding industrial conditions.

Ford: Foundry Equipment and Robot Maintenance

At Ford’s Cologne-Niehl facility, I worked on optimizing foundry equipment and assisting maintenance personnel with robot maintenance and troubleshooting. The facility produces approximately 350,000 EcoBoost engines annually using 17 pressure die casting machines, each with closing forces between 13,000 and 24,000 kN.

The Foundry Environment

The foundry environment presented unique challenges for robotic systems:

• High Temperature Exposure: Operating temperatures up to 820°C for molten aluminum
• Abrasive Conditions: Metal particles and casting debris from the die casting process
• Thermal Cycling: Rapid temperature changes during casting cycles
• Chemical Exposure: Contact with molten aluminum and casting lubricants

The pressure die casting process involves injecting molten aluminum at high pressure into reusable molds, with each mold capable of producing up to 200,000 castings before replacement.

Robot Maintenance and Optimization

My role involved assisting the maintenance team with robot-related issues and developing solution suggestions to make the robots more robust in the harsh foundry environment. Key areas of focus included:

1. Preventive Maintenance Programs

I helped develop systematic inspection and maintenance schedules for critical robot components, including regular inspection of cable harnesses, electrical connections, and mechanical components for wear and tear.

2. Enhanced Protective Solutions

One of my main contributions was suggesting better protective gear for the robots operating in the foundry environment. The robots required specialized protection to withstand high temperatures from molten metal, abrasive particles from the casting process, thermal cycling stresses, and chemical exposure to casting lubricants.

3. Process and Component Optimization

I assisted in modifying robot programming to minimize exposure time in high-risk areas and suggested enhanced protection for vulnerable components like cable harnesses, electrical connections, mechanical joints, bearings, sensor systems, and control interfaces.

Key Learnings

This experience taught me several critical lessons about industrial robot maintenance and optimization:

1. Preventive Approach: Regular maintenance and protective measures are more cost-effective than reactive repairs.

2. System Integration: Robots must be considered as part of the larger manufacturing system, not isolated components.

Conclusion

My experience at Ford’s foundry facility provided foundational knowledge in industrial robot maintenance and optimization. Working alongside maintenance personnel gave me practical understanding of the challenges faced in harsh manufacturing environments and the importance of robust, well-protected robotic systems.

This industrial experience with robots in harsh environments ignited my passion to work on robotics further, particularly in developing solutions that can withstand challenging industrial conditions. The hands-on nature of the work provided valuable insights into real-world engineering challenges and the critical role that proper maintenance and protection play in ensuring reliable robotic operation in demanding manufacturing environments.