One early example of automatic core shop supplied by FRITZ HANSBERG was designed and produced for TRANSTEC AUTOMOTIVE foundry in Northern Ireland.
Built in 1995 to support the production of 3,000 FORD SOHC aluminum cylinder heads per day, this was a truly state-of-the-art core making and handling system, which even today would be the pride of any modern foundry.
HANSBERG’s supply at TRANSTEC included five 60-l, cold-box core machines, and a complete core assembling and handling conveyor system transferring complex cylinder head core packages from the core manufacturing area to the robots feeding the die-casting stations.
Each of the core machines was dedicated to producing one part of the final core assembly requirement, in the following order:
- Machine 1 – WATER JACKET cores.
- Machine 2 – INLET and EXHAUST PORT cores.
- Machine 3 – SLAB cores.
- Machine 4 – OIL ROOM, OIL GALLERY, and CHAIN CASE cores.
- Machine 5 – OIL BREATHER cores.
Three-impression core boxes were used, so that three complete core packages were produced every 60 s.
One complete core package consisted of two main sub-assemblies:
- SLAB core assembly, consisting of the SLAB core with OIL ROOM, OIL GALLERY, CHAIN CASE, and OIL BREATHER cores glued to it. The SLAB core assemblies were put together on the SLAB core assembly conveyor, and then automatically transferred to the upper deck of the double-deck pallets travelling on the core delivery conveyor (see below).
- WATER JACKET / PORT core assembly, consisting of the WATER JACKET, the INLET PORT, and the EXHAUST PORT cores. These cores were not glued together, but simply precisely located to one another on the lower deck of the double-deck pallets of the core delivery conveyor (see below).
The five machines were served by two conveyors, that allowed to form the final packages and present them to twenty-four die-casting cells. These conveyors also provided buffers for both the SLAB core and the WATER JACKET / PORT core sub-assemblies:
- SLAB core assembly conveyor. This was a two-level conveyor facing machines 3, 4, and 5, where the SLAB sub-assembly was put together and glued. The three SLAB cores were removed from the forks by means of a SLAB core manipulator that tilted the cores face-up before depositing them on flat pallets. The other cores were removed from the forks by the operators of machines 4 and 5, who placed them on the SLAB cores after cold glue had been automatically spot-injected by two gluing units. Note that the SLAB core assemblies were formed on the upper level of the conveyor, after which they were lowered to the lower level and transferred backward toward a SLAB assembly manipulator that removed them (again, three-by-three) and placed them on dedicated, double-deck pallets travelling on the core delivery conveyor (see below).
- Core delivery conveyor. This conveyor delivered the core assemblies, precisely located on the double-deck pallets, to six gantry manipulators which removed the core assemblies from the pallets and delivered them to the die-casting cells (gantry manipulators and die-casting cells being supplied by others). Note that the delivery conveyor was designed to deliver its pallets to the six gantry robots in any order, simply upon demand by the die-casting cells.