Action® Digitally Controlled Manipulator 780i

Vulcan’s new Digital Series Action® Manipulator offers the latest technology for material handling applications. In Foundry applications, this machine is typically used at the shakeout to move castings to overhead conveyors or pallet boxes and can be used in forging applications to load and unload furnaces, and tend presses.

Action® Manipulators have undergone a major evolution, driven by reliability, maintainability, efficiency and cost of ownership. At every turn, we have minimized the component count, maximizing commonality and availability, and ensuring ease of maintenance.

The new control design has been engineered with the hand control as the primary user interface. The hand control is instantly intuitive as the operator’s hand motion directly corresponds to the boom motion. An intuitive, user-friendly HMI provides real information during normal operation as well as error/alarm events for improved ease of use.

This new design offers the latest technology in mechanical and hydraulic components, and incorporates industry-standard digital controls that are open, customizable, and expandable with no proprietary components.

Machine Characteristics

Lift Capacity 6,600 lbs (3,000 kg)
Max Casting Temperature 950 °F (510 °C)
Power 120 HP (90 kW)
Radial Reach 19 ft to 6 in (5,791 mm to 153 mm) to the center of grapple tip at 0° Pitch
Floor Height/Cab Height Depends on application
  • Slew (azimuth) – 330° (adjustable)
  • Vertical – 13 ft to 10 in (3,962 mm to 254 mm)
  • Horizontal – 19 ft to 6 in (5,791 mm to 152 mm)
  • Pitch – 90°

Control System

Architecture Open system utilizing standard PLC, HMI and Industrial Ethernet I/O
Location In-cab system allows single-point operation & tuning; 120 VAC outlet provided for maintenance computer
Motion Control PLC controls valves directly, with no driver cards, no proprietary boards
Operator Controls
  • Single-hand control of Lift, Extend (closed loop), Slew (open loop), Grip (directional)
  • 2-axis joystick for Yaw (prop.)(optional), Pitch (prop.), Roll (dir.)
  • Simple, easy-to-read line-up indicators in operator’s field of view.
  • Forcefeedback system.
Status Display
  • HMI displays system operating parameters, provides for remote grip pressure adjustment, etc.
  • HMI displays error information to aid in diagnosing faults
Discrete Controls Master start, stop, E-stop are hardwired for durability
Peripheral Control Network I/O to HPU minimizes cabling, provides for connection of I/O node to control/monitor conveyors, etc.
Safety Foot pedal enables machine motion; safety relay provided for connection of external interlocks

Operator Cabin

Mounting Can be mounted left- or right-hand; 42” (1065 mm) elevated mounting for good operator visibility of conveyors
Construction Fabricated structure; Double insulated safety glass windows; noise insulation for <85 dbA in cab at 100 dbA ambient outside noise level
Seating Large, ergonomic operator seat, with adjustable positioning, up/down, back/forth, back tilt +/-
Access Standard cab steps for standard elevation; other options available

Control Advantages

  • Open-architecture control system utilizing industry-standard commercially available components.
  • No proprietary hardware, highly customizable.
  • Complete control system utilizing network I/O.
  • Minimized cabling increased reliability, Ethernet connectivity.
  • System status, error/fault indications plainly displayed on the HMI.
  • Intuitive diagnostics, with no error codes or LEDs to decipher for diagnostics.
  • PLC controls all valves directly.
  • Motion control tuning is performed entirely from the cab with GUI on HMI.
  • No external driver cards or proprietary boards; fewer connections; simplified maintenance/optimization.
  • “Soft” limits can be easily programmed from HMI for the closed-loop axes.
  • Envelope can be constrained to fit virtually any scenario.
  • Network I/O connection at HPU and customizable HMI in cab.
  • Virtually infinite possibilities for monitoring/controlling peripheral equipment from the manipulator cab.

Overall Advantages

  • Extensive use of FEA and 3D computer modeling to optimize structural geometry, joints and members, resulting in low unit stresses, minimum power consumption and maximum reliability.
  • Non-proprietary hydraulic cylinders are used throughout. Primary axis cylinders are identical to minimize part inventory.
  • Bearings, valves, electronics, and other non-proprietary components are readily available from multiple sources for cost-effectiveness.
  • Best of both worlds… superior performance and reliability, with industrial-standard components.

Several standard models with 500 to 3000kg payload capacity are available with sweep envelopes to meet individual customers’ requirements. Attachments are also available for a wide variety of applications such as hot casting grapples, Riser knockoff Impactors™, and Combination Grapple/Impactors™.

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