Modernisation of Foundry Production with Industrial Robots and Manipulators

Abstract

The modernization of foundry production through industrial robots and manipulators represents a significant advancement in automation, efficiency, and occupational safety. The foundry industry plays a crucial role in the manufacturing sector, providing high-quality metal products for various applications. However, traditional foundry processes are often labor-intensive, hazardous, and prone to inefficiencies. In recent years, the integration of robotics and automated technologies has become an essential aspect of improving productivity, ensuring precision, and enhancing workplace safety. This study focuses on the application of industrial drones in foundry production, particularly for material transportation, coating application, and quality control. The research explores the feasibility of integrating the DJI Matrice 300 RTK drone into the casting process, analyzing its potential benefits in optimizing logistics, minimizing defects, and improving overall process efficiency. The use of drones in foundry operations offers several advantages, including the ability to operate in high-temperature environments, automate routine tasks, and reduce human exposure to hazardous conditions. To achieve these objectives, the study employs a combination of theoretical analysis, mathematical modeling, and experimental testing. A mathematical model of drone movement within the foundry environment is developed to optimize flight paths, minimize energy consumption, and ensure precise navigation. Additionally, simulations are conducted to assess the impact of high temperatures and airborne particles on drone performance. Experimental trials are carried out in real production conditions to validate the proposed approach and evaluate the efficiency of drone-assisted operations. The results of the study indicate that industrial drones can significantly improve foundry logistics by reducing material transportation time and ensuring the precise application of protective coatings. The implementation of automated aerial systems enhances quality control by enabling real-time monitoring of casting processes and early defect detection. Moreover, the reduction of human involvement in hazardous tasks contributes to workplace safety and minimizes occupational risks. Based on the findings, recommendations are proposed for optimizing the integration of drones into foundry production. These include refining navigation algorithms, enhancing thermal protection measures, and developing advanced sensor technologies for improved defect detection. The implementation of these recommendations can lead to higher efficiency, reduced waste, and increased competitiveness in the foundry industry. The study's outcomes have been applied in practical settings, including their adoption at PJSC "Kamet Stal" and incorporation into educational programs to enhance training in industrial automation. The research highlights the transformative potential of drone technology in modernizing foundry production and underscores the importance of continued innovation in automation and robotics. Future research directions include exploring alternative energy sources for drones, improving their adaptability to extreme environmental conditions, and expanding their functionality for broader industrial applications.