AISTech 2017

AISTech 2017

AISTech 2017

Vulcan Engineering Co. will be at AISTech 2017 Nashville, TN May 8th-11th.
Visit us at Booth #1959.

Learn more about:

Vulcan’s line of Mid-West Machine™ equipment is specifically designed for ease of maintenance and operation & offers metal conditioning solutions built to meet the needs of steel mills, Ingot producers, forge shops, and titanium producers.

The Fox® line offers improved productivity for spot grinding of defects and conditioning of smaller products. Fox® equipment is offered in both manual and semi-automatic configurations.

Metalcasting Congress 2017

VE Booth 602



Vulcan Engineering Co. will be at the 121st AFS Metalcasting Congress 2017 in Milwaukee, WI April 25th-27th. Visit us at Booth #602.

Learn more about:

  • Complete Engineered Foundry Systems & Facilities
  • Robotic Automation & Integration
  • Lost Foam Systems & Equipment
  • Mold Handling Systems
  • Robotics and Automated Finishing
  • Grinding & Cleaning Equipment
  • Much more for your foundry needs

New Sales Engineer

Josh Schaffer

New Employee at Vulcan Engineering Co. to assist our Sales Team

Joshua Schaffer

Josh Schaffer

Sales Engineer to our Engineering/Capitol Equipment lines

Vulcan Engineering Co. (Helena, Alabama, USA) announced that Joshua Schaffer has been named Sales Engineer to our Engineering/Capitol Equipment lines. His position will entail developing and maintaining foundry solutions while fostering relationships with customers both domestically and internationally. Josh graduated from Middle Georgia College and started his career in the Aerospace field before entering the US industrial/foundry market and now has over 13 years of experience in the industry.

Tel: 205-685-4425
Email: schafferj@vulcangroup.com

New International Team Member

Jack Yu

New Chief Representative of Sales in China at Vulcan Engineering Co.

Jack Yu

Jack Yu

Chief Representative of Sales in China

Vulcan Engineering Co. (Helena, Alabama, USA) announced that Jack Yu has been named Chief Representative of Vulcan China & Asia Sales Director. His position will accommodate the growth and increasing marketing demand for Vulcan’s Lost Foam Systems & Equipment line, Investment Casting Systems & Equipment line, Finishing Equipment such as grinding and cutting machines, as well as Foundry-duty Manipulators & Robotics in China. Jack Yu has 4 years’ experience in the foundry plant setting and 14 years of sales and marketing experience in foundry equipment and foundry materials field.

Tel: +86-139-1557-4670
Email: yuj@vulcangroup.com

Foxall® Offers Major Benefits to Benton Foundry’s Cleaning Operations

Foxalls Installed

Benton FoundryBenton Foundry in Benton, Pennsylvania USA, is a state-of-the-art ductile and gray iron, green sand foundry. Their six automatic molding centers produce industrial castings which can be very intricate with up to 50 chaplets in a four-core assembly. The Foundry has been in production for more than 160 years and the Hall family has been in the foundry industry for nearly 100 years.

In 2006, as a result of significant growth and a desire to further improve efficiency, Benton began evaluating its finishing processes. Benton foresaw the approaching change in demographics, recognizing that finishing room personnel were going to be more difficult to hire and even harder to retain. As an added challenge, one of the reasons for their growth is that they were expanding their market focus, adding a new molding line that would accommodate castings up to 250 lbs. The finishing area was not set up to accommodate castings of that size efficiently, and manually handling castings over 50 lbs. would not be part of the plan.

After successfully working with Vulcan Engineering in the past, Benton began the process of adapting the Foxall® Automated Casting Finishing cell to fit their finishing needs. Several parts were sent to Vulcan for evaluation and testing. Then, Vulcan worked with Benton’s team to fixture, program and grind the parts. President of Benton Foundry, Jeff Hall, stated that, “… a great benefit was having three of our employees at Vulcan for several days getting familiar with the process.”

Once the Foxall® was installed, the desired production was achieved with much more consistent parts. Fixturing and programming could be accomplished easily, quickly and inexpensively. The retention of operators over grinders has been a success, and abrasive costs were also greatly reduced. The robotic grinder’s closed capture ventilation was an added asset. This feature later proved to be an even greater potential advantage in light of the proposed silica regulations.

Foxalls InstalledIn 2010, Benton installed a second Foxall® system. This particular unit was the first unit that Vulcan equipped with Force Control. This technology monitors the force on the spindle, allowing the robot to be programmed to run faster than units without this feature. Also, the use of Force Control helps to protect the robot from mechanical abuse that could lead to costly repairs.

Benton recently added two more units, including a larger Foxall® 636 unit that further exceeded expectations, and significantly reduced the payback period when grinding castings up to 250 lbs. “Generally, the larger the casting, the greater the productivity improvement. On the large end of our production envelope, we have had two operators replace seven floor grinders. In addition to time savings, both casting finish and consistency of grind have improved. The former floor grinders have been redeployed and the grinding room is a quieter, cleaner venue,” said Jeff Hall.

Throughout the industry: floor, bench, and stationary grinding have historically been very labor intensive with positions predominately held by men. Robotic grinding is a game-changer in that regard. Operator fatigue is decreased, safety is increased and fewer personnel are needed. Plus, it is easier to find employees for machine operators than for manual grinders. The work is generally suitable for men and women of all ages, thus significantly increasing the pool of potential candidates to run these systems.

Quality Control at Benton has experienced a decrease in parts that need to be reworked and/or scrapped since the dimensional consistency of ground parts has greatly improved. This decrease in unacceptable parts is also due to having steady, accountable operators. Jeff Hall says, “The robotic cells are there every day, never take a shortcut, and remember all their instructions.”

Over the years, Benton has improved the process of automation in their cleaning room by:

  • Adding hoists and other equipment for faster and easier material handling.
  • Continuing to work with Vulcan Engineering on additional features and programming options for their Foxall® systems.
  • Working with individuals in the abrasives industry to be able to grind faster, longer and more accurately while using a variety of tools.

Currently, Benton is operating four (4) Foxall® units. Benton Foundry has an objective to continue their efforts to improve automation, while streamlining the existing cleaning and grinding operations to be able to robotically grind ~70% of all product within the next 3-4 years.


 

Benton Foundry, Inc.
5297 State Route 487, Benton, PA 17814-7641 | 570-925-6711
benton@bentonfoundry.com | www.bentonfoundry.com

Cost Estimator for Specialty Foundry Equipment

cost-estimator

Vulcan Engineering Co., an established Manufacturer and Integrator of Foundry Equipment and Systems including Foundry Processing Equipment, Robotics, and Grinding equipment for the Foundry Industry located in Northern Shelby County is seeking an Estimator to interact with Sales, Project Management and Design Engineers to develop cost estimates. The correct individual must have a desire to understand how things work mechanically and control-wise and use this knowledge during the development of estimates. Good communication skills are a must as the successful individual will be interacting with Sales Engineers, Project Managers, Design Engineers, Vendors and Company Management.

This position requires a minimum of 2 years of estimating experience in a design, manufacture and installation environment and also a minimum of a 2-year technical degree. Must have a good working knowledge of Microsoft Office with an emphasis on Excel along with basic knowledge of AutoCAD with the ability to read, interpret and prepare takeoffs of both concept and historical mechanical drawings.

Please provide a brief summary about yourself (or cover letter) along with your resume, salary history, and salary requirements via email to employment@vulcangroup.com or fax to (205) 663-1493. Please be sure to title the subject field as “Cost Estimator

Sales Engineer

sales-engineer

Vulcan Engineering Co., an established manufacturer and integrator of Foundry Equipment and Systems including Foundry Processing Equipment, Robotics, and Grinding equipment for the Foundry Industry is seeking a Sales Engineer to interact with international and domestic customers. The correct individual must have a desire to understand how things work mechanically and control-wise and use this knowledge and natural problem solving skills during the development of solutions to be presented to the customer. If you desire a position where you do not do the same thing every day, a fast learner, and eager to contribute to the growth of the company as well yourself, this position is for you.

The position requires a minimum of two years work experience selling equipment and systems to the foundry industry or similar experience selling capital equipment/projects to other industries, an engineering degree, working experience with AutoCAD, basic word processing and spreadsheet skills, and travel. Competitive salary and benefits.

Please provide a brief summary about yourself (or cover letter) along with your resume and salary requirements via email to employment@vulcangroup.com or fax to (205) 663-1493. Please be sure to title the subject field as “Sales Engineer

Foundry Systems Sales Engineer

Foundry Sales Engineer

Vulcan Engineering Co., Helena Alabama, is searching for seasoned qualified foundry experienced candidates to expand their Worldwide sales and marketing presence.

Successful candidate must be a confident self-starter with several years of foundry experience. Plant engineering and capital project development experience a major plus. Manufacturing experience also an advantage. Must be able to comfortably maneuver in foundry sites globally developing and discussing upgrades, expansions and improvements in both Green Sand and Nobake processes. Vulcan “solutions” will include not only equipment designed and built within the large manufacturing site at Vulcan… but also the integration and commissioning of all other foundry equipment provided by other OEMs as well.

Must be able to conceive, develop, and promote not only new Greenfield sites, but also modernization and upgrade plans for existing facilities. Total project solution and development requires initial travel to and from foundry sites primarily in North and South America. Occasional limited involvement in other regions on an as needed supportive basis.

Vulcan Engineering supplies a range of specialized “solutions” for the metal casting industry including but not limited to integration of sand coolers, sand handling equipment, mold handling systems, and specialized heavy duty equipment for the metal casting industry. Focus directed not only to experienced design and custom supplied and manufactured equipment, but also the integration and commissioning of the same. On site foundry audits performed with a sharp focus on process controls in Green Sand and Nobake. Although Robotics, Investment Cast, Lost Foam, and large grinding systems are a core portion of the diversified Vulcan line of equipment, THIS position will focus primarily on the development of traditional Green Sand and Nobake applications.

Please provide a brief summary about yourself (or cover letter) along with your resume and salary requirements via email to employment@vulcangroup.com or fax to (205) 663-1493. Please be sure to title the subject field as “Foundry Systems Sales Engineer

Updated Foxall® Controls for Improved Finishing Technology

HMI-Overview-650x365Vulcan has recently made several updates to the Foxall® with new system controls and an operator interface that is more user-friendly than ever. This system has always offered simple programming (online or offline), but now software updates make it more efficient and easier to use.

The operator interface features a touch screen HMI where the operator can access Equipment I/O status, Recipe Management, Alarms and PM reminders, Password Protection, and has the ability to connect to the customer’s network. Another advantage is Remote Online Diagnostics which permits Vulcan real-time remote access to the control system and all parameters/programs. This simplifies diagnostics and support while minimizing down-time.

An optional Force Control Function allows the next level of adaptability and optimization. This tool improves grinding efficiency by using a force/torque sensor mounted between the robot and the spindle. Now the system can automatically change TCP speed in response to feed force, therefore improving material removal rate and accuracy.

Additional system updates include:

  • Live view interior camera to safely monitor the system while in operation
  • New Software for simplified upgrades
  • Software is not OS-dependent, Java based for compatibility
  • Updated Hardware
  • All Electrical components that are off the shelf and readily available
  • Safety measures that meet current industry standards
  • Industrial computer with touch-screen operator interface

Existing, proven technology and features:

  • Simple part fixturing
  • Bar code that allows for automatic program loading
  • Six degrees of freedom that provides virtually unlimited access of the robot to the part
  • Facilitates fast fixture change
  • Ample program storage
  • Optional automatic quick-change spindle that accepts an array of tools as needed
  • Self-contained construction and simple utility hookup that allows for easy relocation with no calibration or re-teaching necessary to restart production.
  • Off-line programming during production

Together these updates and the existing technology allows several advantages such as monitoring of machine and operator performance through information such as production numbers and cycle times. It is also simple enough to use that operators can be trained in just a few hours. The improved control system, in addition to its already flexible design, makes the Foxall® one of the best options on the market for automated casting finishing cells.
If you want to provide fast, reliable, consistent product finishing or would like to learn more information on the Foxall® and its capabilities, please visit the Foxall® page.

ICI Expo 2016

ICI Logo
Vulcan Engineering Co. will be at the 2016 ICI Expo in Columbus, OH October 16-19. Visit us at Booth #220.

Learn more about:

  • Complete Engineered Foundry Systems & Facilities
  • Robotic Automation & Integration
  • Investment Casting Systems & Equipment
  • Mold Handling Systems
  • Robotics and Automated Finishing
  • Grinding & Cleaning Equipment
  • Much more for your foundry needs

View Our BoothView Our Booth