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FullSharp installed a pneumatic manipulator with a gripping head in a metal casting area, where molds and castings have to be pulled out and set in on the furnace rhythm. The operator stands at the handle end, well clear of the hot zone, while compressed air carries the full weight and the job becomes guiding the piece into place.
The casting area is both heavy and hot, with molds and castings needing to be pulled out and set in on the furnace's own rhythm. Manual handling is slow, forces workers close to the heat source, and puts them at real risk of burns or back injury.
FullSharp installs a pneumatic manipulator with a gripping head that holds the workpiece firmly, while the operator stands at the handle end, well clear of the hot zone. Compressed air carries the full weight of the load, so the operator's job becomes guidance only, placing the workpiece exactly where the production rhythm calls for it.
A pneumatic manipulator working at the mold casting area of a metal plant.
Equipment Installed
- Pneumatic manipulator arm: an air cylinder carries the load, so only a small effort is needed to move the workpiece.
- Workpiece gripping head: jaws shaped to the mold and workpiece, holding firmly through turning and tilting.
- Working-end swivel joint: rotates the workpiece on its axis to set it into the mold or conveyor at the right orientation.
- Valve and air filter assembly: keeps pressure steady, so the load does not drop when air flow varies.
Benefits for the Plant
Safety in the heat zone
The operator stands at the handle, without reaching close to the hot mold.
Keeps production on rhythm
Each pick-and-place cycle is fast and consistent, independent of an operator's strength.
Fewer back injuries
Compressed air carries the load, so workers no longer strain to lift through a full shift.
Actual Installation Photos
Click a photo to enlarge. A 36-photo gallery from the actual site.
Suitable Applications
- Foundries and metal casting plants
- Hot stamping and forging shops
- Press mold-change stations
- Heavy machined-part fabrication
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Frequently asked questions
How do you handle hot castings without burning workers?
Use a manipulator with a gripping head and a long arm, so the operator controls it from the handle end away from the heat source. The gripper holds the piece and compressed air carries the weight.
Can a pneumatic manipulator lift heavy molds?
Yes. The air unit carries the load and the operator only guides it. The capacity and gripper shape depend on the real mold or casting, so FullSharp surveys the parts and work cycle before choosing the configuration.
Where are foundry manipulators used?
Foundries and metal casting plants, hot stamping and forging shops, press mold change stations and heavy machined part fabrication are typical users.
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Consulting for Your Plant
FullSharp weighs the heaviest workpiece, measures the travel distance from the furnace to the set-down point, and records the ambient temperature to select the gripping head material. Our engineers also calculate the reach and anchor point for the manipulator column. Contact FullSharp to schedule a plant survey.