Author Archive for Scott – Page 2

FundiExpo 2016 – Mexico

Vulcan Engineering Co. will be at FundiExpo 2016 in Queretaro, Mexico Oct 5th – Oct 7th. Visit us at booth 716.

Learn more about:

  • Complete Engineered Foundry Systems and Solutions
  • Foundry Engineering Additions, Renovations, Expansions, and Project Management
  • Robotic Automation & Integration
  • Robotics and Automated Finishing
  • Casting Finishing, Grinding, & Cut-Off
  • Heavy-duty Manipulators
  • Much more for your foundry needs

Floor Layout

Ankiros 2016 – Turkey

Vulcan Engineering Co. is partnering with LMA and will be at the Ankiros 2016 in Istanbul, Turkey Sept 29th – Oct 1st. Visit us in the LMA booth at Hall 3 C110/A10.

Learn more about:

  • Fox® Finishing Equipment including Grinders, Cut-Offs, and Casting Positioners
  • Robotics and Automated Finishing including Action® Custom Finishing Cells and Foxall® Part Finishing Cells
  • Action® Heavy-duty Robots and Manipulators
  • Much more for your foundry needs

Logo Info

High Capacity Rollovers

Donovan High Capacity RolloverDonovan™ Mold Handling equipment is designed to handle, roll over and close cope, drag or complete molds or flasks. This equipment can hold different molds level regardless of center of gravity. Vulcan Engineering has built capable hydraulic systems that can run continuously without overheating. Self-contained hydraulics ensure low maintenance, trouble-free operation.

Securely hold molds for core setting, venting, cleaning and closing, without loss of position. Eliminate the use of belts and chains by employing the long-wearing gear drive. Systems and equipment are available for use on molds with flasks as well as flaskless (nobake) molds.

This particular Gantry Style Rollover is designed to move over a conveyor to draw the flask package, lift and move the flask to a coating area. Once there, the Rollover will rotate the flask 70 degrees to allow for manual coating of the mold. After coating, the rollover will move the flask to another conveyor and set the flask on a bottom board to transfer to curing. As with any Vulcan product, we can customize this equipment to fit your foundry’s needs.

GIFA 2015

Vulcan Engineering Co. will be at the GIFA 2015 in Dusseldorf, Germany June 16th-20th. Visit us at Booth #16/D11.

Learn more about:

  • Complete Engineered Foundry Systems
  • Robotic Automation & Integration
  • Robotics and Automated Finishing
  • Casting Finishing, Grinding, & Cut-Off
  • Much more for your foundry needs

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Increase Safety in Cut-Off Technology

Vulcan Engineering incorporates the latest in advanced safety features while still offering reliable efficient equipment.

Fox Air Float - CuttingThe Fox® Air Float Cut-Off machine is ideal for gate and riser removal on small to medium size castings, or castings on runner bars or trees. It is well suited for processing castings that are too heavy for operators to handle, as the air float feature makes moving large weights almost effortless. Compressed air is used to “lift” the gondola to allow the operator to “float” it around the table, and use the laser guide to align the casting into the proper cutting position. Once in position, a vacuum is used to securely hold it in place during cutting. The saw uses hydraulic down pressure for fast efficient removal of risers and gating.

The saw shown is designed to be installed in its own room; other models are available with full enclosures for installation around other workers Fox® grinding and cutting equipment has proven reliability, and is designed to work effectively in rugged, dirty foundry environments. Precise cutting and efficient processing is only part of the design, to truly enhance this system Vulcan has added several advanced safety features.

  • Rotary Wheel Guard: This machine incorporates a rotating wheel guard. This allows the operator to move, re-align, and change castings safely without having to turn off the motor each time. The wheel guard technology includes sensors that are connected to a safety circuit. When pulling the handle down to start cutting the guard opens, allowing the operator to perform a cut.
  • Operator Safety Door: The operator safety door has a Lexan window with an easily replaceable Plexiglas splatter shield. This allows the operator to be protected from debris while still being able to see the material being cut. The safety door is interlocked with the safety circuit allowing the saw to only be operated when it is closed.
  • Operator Console with Safety Lockout Key: When the operator has to change the cutting wheel, the system must be shut down. To ensure all operations are powered off or de-energized, a safety key is incorporated into both the console and the outer wheel guard. The safety key must be inserted into the dead bolt lock on the wheel guard to allow the guard to be opened to change the wheel. Once the wheel is changed and the guard properly closed, the key can be removed and inserted into the control console allowing the saw to operate again.
  • E-Stop Functionality: There are 3 different E-Stop switches that can be utilized in this system. There are two push-button stops, one on the operator console and the other located on the electrical panel. The third option is an emergency kick switch tied to the E-Stop system for quick, hands free use.

All of the above features, as well as incorporating redundant safety shutoff valves with monitoring, make this one of the safest cut-offs on the market.

Metal + Metallurgy China 2015

Vulcan Engineering Co. will be at Metal + Metallurgy China 2015 in Shanghai, March 31st – April 3rd. Visit us at Booth 1N51.

Learn more about:

  • Complete Engineered Foundry Systems
  • Robotic Automation & Integration
  • Robotics and Automated Finishing
  • Much more for your foundry needs

Click to enlarge the image below to view where our booth will be located at the show.

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Multiphase Plant Upgrades & Expansion

Progress well underway for multiphase plant upgrades and expansion to Lodge Manufacturing Company.

Lodge Manufacturing Company, South Pittsburg, Tennessee, has begun a multiphase plan for expansion and upgrades to their existing, highly successful foundry. “This is more massive than anything we’ve ever done before,” stated Henry Lodge, President & COO of Lodge Manufacturing and great grandson of the business founder, Joseph Lodge. “We are excited and we need this additional production.”

Lodge Sand System Upgrades“In 2009 we looked at five year projections showing sales would exceed current production capacity by 2015. That is when preliminary discussions started about our expansion,” Lodge stated. With this realization, Lodge had to consider current needs as well as future goals. In addition to a significant increase in capacity there would need to be ongoing considerations to maintain employee safety, increase the effective use of labor, enhance operational efficiency and provide for continuous product quality improvements overall while still allowing for future growth.

Lodge approached Vulcan Engineering Co. to discuss the next steps in making expansion a reality. With a history of working with Vulcan on past projects, Lodge took into consideration the relationships built over the years as well as the consistency of work; from sound industry advice to the quality of process planning and engineering. “Clearly Vulcan has plenty of knowledge and experience. They work to identify the potential problems and bring them to us; we don’t have to find them later,” said Henry. “I knew we could trust them with this job, and I can sleep a lot easier,” stated Michael Whitfield, Lodge Vice-President.

“Vulcan listened to our needs and goals for the future. They developed two different approaches to achieve our desires, allowing us to decide which method would be the best fit. Our main operational requirements were that the foundry could not shut down during construction and that the newly expanded foundry be designed in such a way to allow for additional growth in the years ahead,” Whitfield stated. “Once we selected the plan Vulcan developed a reasonable, economic plan utilizing three distinct phases to achieve our overall goals. The design was a structured approach to maintain ongoing existing capacity while installing the infrastructure for our future capacity requirements.”

Installed Melting SystemPhase I began with the addition of new melting capacity by expansion and additions to the foundry building in such a way as to not only avoid disruption of existing operations, but also improve melting efficiency and material flow through the process. The new melting systems and metal delivery equipment began production earlier this year. The initial phase will complete later this year with the startup of additional high volume fully automated sand, molding, pouring and casting handling systems.

Phase I also incorporates all design and equipment specifications to allow for future expansions which will ultimately replace all existing molding lines with new, state of the art, higher output equipment. With this design approach each additional phase completed will further enhance efficiency and output of casting production. For each additional expansion, an entire molding system will be replaced and prepared sand capacity will be increased for the additional demand created. Although prepared sand and casting tonnage will be increasing with each additional phase, the Phase I handling equipment has been designed and installed with the capacity to accommodate full future demand of the foundry through Phase III.

Lodge Interior Panorama“With Phase I of the project nearly finished, Lodge is on track to continue with this plan of updating and expansion over the years to come. This will also make work easier on our employees in terms of environment and safety. The layout leaves plenty of room to work.” In closing, Henry Lodge stated, “The biggest plus is being able to meet customer demand. Customers, it’s all about the customers! We can be comfortable growing the business and accept new customers when we are confident we can meet the increased demand while also having the utility to grow even more. While it is all about the customer, it is our hard working and dedicated employees who have built the Lodge brand through quality workmanship. We are not doing this just for now, we are thinking about 10-20-30 years ahead.”

Automate 2015

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Vulcan Engineering Co. will be at the Automate 2015 in Chicago, IL March 23rd-26th. Visit us at Booth #221.

Learn more about:

  • Complete Engineered Foundry Systems
  • Robotic Automation & Integration
  • Robotics and Automated Finishing
  • Much more for your foundry needs

View Our Booth

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Metal Casting Congress 2015

2015 Metal Casting Logo
Vulcan Engineering Co. will be at the 2015 Metal Casting Conference in Columbus, OH April 21st-23rd. Visit us at Booth #306.

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

View Our Booth

The Power of a Robot in a Man’s Hand

Since Vulcan Engineering Co. launched to the new VTS™ (Vulcan Tactile System) in January of last year, there have been many questions. Vulcan has been using the phrase “Robotic/Manipulator” because it just seemed to fit. However, this might have caused a few bewildered looks. Simply, the VTS™ is the best of both worlds and can be used as a Robot or as a Manipulator.

Some have seen images of the system and quickly assume that this is just another way to use robots for automation… not quite. Although the VTS™ utilizes an industrial robot, this system is not just for programming and walking away while the robot does the rest (albeit, that is one of its capabilities). We in this industry know what industrial robots can do, so what’s different about the VTS™?

VTS Inside with OperatorUsing leading edge robotic/manipulator technology paired with Vulcan’s specialized hand control system, this telemanipulator allows the operator to manually control the robot’s movements. That means the operator moves the robot simultaneously with his hand movements for a true “hands on” experience. Some might compare this to jogging with a teach pendant, but Vulcan’s hand control system is very different.

First, the operator’s hand position likewise commands the robot’s “hand” (tool) position. Unlike jogging with the teach pendant (velocity control mode) that is difficult to coordinate motions of multiple axes, the VTS™ controls provide very smooth and precise movements. Movements can be scaled up or down as needed for the task at hand. One might say it moves with surgical precision. Secondly, there is force sensing at the robot’s tool that is transmitted back to the operator’s hand. This provides a feel of the forces the operator is applying with the robot. Another way to explain this is to think of the operator as holding the tool on the end of the robot. Wherever his hand moves, the machine is following his motions performing the work with multiples of force and speed.

The unique design and flexibility of the VTS™ enables floor operators, unskilled in robotic programming, to utilize the full range of control over robotic equipment in fully manual and semi-automatic modes. In addition, this same equipment system, utilizing dedicated fixturing, ordinary robotic programming and only minor adjustments can then also be applied to fully automatic tasks.

VTS Floor Mounted Model - Grinding with Positioner, To clarify, the VTS™ is intended to be a manual machine a manipulator. BUT, with a few add-ons of equipment, it can be utilized as a fully automatic (unattended) robot. This might be useful if you have a need for manual processes some of the time and automatic processes at other times.

The configuration pictured here is the VTS-G model. This machine is provided with a high-power grinding attachment for a tool. With this, the operator can grind and cut around the outside and inside of castings. In addition, the model shown is mobile. The whole unit can be moved via stacker crane or rail-car. This makes it possible to access a very large working envelope. The envelope is only limited by the working envelope of your crane or the length of your rails.

Putting these features all together, the operator of Vulcan Engineering’s VTS™ can perform a job manually by using the power of a robot no matter the application. For more information on the VTS™ and its “hands on” capabilities