Robotics and automation have long been the standard in steel and non-ferrous metals companies, in foundries, forges and metal processing businesses. Driven by digitalisation and artificial intelligence, the metal sector now faces its next innovation boost in the form of autonomous systems and drones. XPONENTIAL Europe will offer new impetus; as the new platform for autonomous technology and robotics, this trade fair will be held in Düsseldorf from 18 to 20 February. As the leading forum for uncrewed systems and robotics in all areas of autonomous technology, XPONENTIAL Europe joins the “Bright World of Metals” with its four trade fairs GIFA, METEC, THERMPROCESS and NEWCAST.
From core manufacturing to smelting and the finished cast part, robots have become an indispensable part of many foundries. Innovative light-metal foundries like those of BMW in Landshut manufacture housings for electric motors with automated casting systems such as the Fill’s vacuum dosing system Robocast V. Robotics for receiving, manipulating and dosing aluminium melt with minimal oxidation guarantee the best possible cast-part quality and save on recycled materials at the same time.
Foundries: Robots are standard
Robots have long been a core component of foundries. At automatic die casting machines, the cast parts are passed on to robots and then checked, fed through deburring presses and run through the subsequent processes. At iron foundries, robust robots adapted to the harsh foundry environment grind and deburr cast parts, and in the core shop, industrial robots take over core handling, assembly and coating.
The steel industry is no different. For example, industrial robots stack hot-rolled steel parts with a weight of up to 2.5 tonnes at Mannstaedt, the global market leader for special profiles. At steel distributor Kloeckner Metals Germany in Bremen, a robot-based system deburrs flame-cut steel parts weighing up to 750 kg for shipyards, shipbuilding suppliers and machinery manufacturers. While the deburring of large and heavy steel parts used to be carried out manually, this physically strenuous and dangerous task is now performed by the robot system, which saves time and cost and is safer and more precise according to Kloeckner.
Drones gather data in hard-to-reach areas
The deployment of drones in steelworks could enable inspections of blast furnaces, cooling towers and other critical components at a whole new level. Multicopters like the Flyability Elios 3 with a 4K camera, thermal imaging and Lidar gather precise data in hard-to-reach areas like chimneys and high rack warehouses. This technology promises early-stage damage detection, saves time and ensures maximum safety for inspection staff.
It is hardly surprising that major metallurgical plant manufacturers have included robotics in their product range to increase safety and productivity for quite some time.
Robotics is a component of metallurgical plant technology
One example of this is the company SMS, which developed the robotic application X-Pact Sampler as a substitute for the dangerous manual operations of temperature measurement and sampling from a molten steel bath. The sampling robot is capable of performing both simple functions and fully automated cycles that include removing cartridges from the magazine, cutting and dispensing samples, scraping used cartridges, compensating for lance deformation and managing lance changes.
Primetals also aims to improve safety and occupational health in steelworks with its robotics solutions. For instance, the LiquiRob robot system carries out several hazardous tasks in the Thai steelworks of steel producer Siam Yamato Steel, including using the oxygen lance, taking measurements and samples from the tundish and feeding powder into the tundish.
Autonomous robots ensure safety in steelworks
Driven by digitalisation and artificial intelligence, the metal sector now faces its next innovation boost in the form of autonomous systems and drones. For example, Outokumpu is the first company in the steel industry to use AI and autonomous robots in safety management. To this end, the global market leader in the stainless steel sector signed a cooperation agreement with Swiss robotics company ANYbotics on autonomous robot solutions in 2023. The ANYmal robots support Outokumpu’s ambitious safety strategy and goal of creating the safest working environment in the steel industry.
XPONENTIAL Europe – the new platform for autonomous technologies and robotics
Further impetus for the use of autonomous technologies and robotics in the metal industries will be provided from 18 to 20 February 2025 at XPONENTIAL Europe in Düsseldorf. The new leading forum for uncrewed systems and robotics in all areas of autonomous technology is part of Messe Düsseldorf GmbH and adds new autonomous technologies to the “Bright World of Metals” with its four trade fairs GIFA, METEC, THERMPROCESS and NEWCAST. For instance, Sandvik Osprey intends to present the potential of digital production processes and new technologies using metal powder at XPONENTIAL Europe. According to the company, it is the world’s leading producer of metal powders for metal injection moulding and additive manufacturing.
Source: Messe Düsseldorf
