IR4

Automated Metal Spray

OUR Projects

Automated Metal Spray

OUR Projects

Automated Metal Spray System

The IR4 team engaged with Westrac, Tomago to provide a solution to efficiently metal spray multiple Caterpillar wear parts with an Inverted 7th Axis Robot design. The solution was configured with a powered trolley for simplicity of loading / unloading parts outside of the spray booth. The system was designed to rotate wheel hubs from Caterpillar Haul Packs and also accounted for engine blocks to respray the cylinder head surface. The system was installed 1stQtr 2021 and is proving a valuable addition to the customer requirement. Costly Rework is eliminated, the speed and efficiency of the system means productivity is high and repeatable quality is guaranteed.

The IR4 Robotic Metal Spray solution can also be retrofitted with a different process such as Laser Cladding depending on finish requirement.

The system can be also configured to accommodate a multitude of different parts. 

THE JOB
  • Provide an automated solution, removing the operator from the hot works area where the coating is applied, improving safety
  • Provide a robotic solution that could access all areas where coating was required enabling repeatable uniform coating
  • Provide a solution that catered for a wide variety of parts including many Caterpillar Engine blocks and wheel hubs
  • Offer an operating system that is easy to use and does not require trade level staff to operate
SCOPE OF WORK
  • 7th Axis Inverted Robot with loading unloading trolley
    • Cater for Full Array of Caterpillar Engine Blocks
    • Integrated horizontal rotation of Caterpillar wheel hubs
    • Fully Enclosed System with operator isolation
    • Parametric Programming for ease of use
Other Optional Configurations
  • 7th Axis Inverted Robot loading unloading trolley incorporating vertical rotator
  • 7th Axis Inverted Robot with static vertical rotator
  • Wall Mounted Static Robot incorporated with floor mounted vertical rotator
  • 7th Axis Vertical Robot with vertical rotator
THE DELIVERABLES
  • The project was successfully completed and installed on time and on budget, key deadlines were met. The successful outcome is due to:
    • IR4 collaborating with the Westrac team to deliver a high-quality solution for their metal spray requirements was key to meeting project deliverables.
    • IR4’s in-house resource capability delivered a best-in-class solution with output volume 40m³
    • Processes a full array of parts with ease of use for semi-skilled operator through parametric programming
    • Processes blocks up to 3.2m length and hubs up to 2m
    • Capable of processing smaller parts if required
    • Under six minutes to coat 3500 Series V16 Engine Block @ 50 microns