Münstermann has modernized a setting plant for refractory bricks for RHI Magnesita. An old unloading gantry loader was replaced by a robot setting system.

The main element of the modernization was the replacement of aunloading gantry for unloading tunnel kiln cars by a flexible robot solution. Here, a so-called shelf robot is used. It is a special type of robot that can work below or at the same height as the platform. In the present case, the robot stands on a platform under which the kiln cars pass.

Setting pattern generator included

The robot can be programmed via a special software including setting pattern generator. This software is already used on other systems of the customer, so that the operation of the robot in the factory is already known. The modernization also included a new tunnel kiln car transport system with a hydraulic car clamp for positioning the kiln car and a 7-fold vacuum gripper for kiln car unloading.

Control system and security concept

Of course, due to the conversion, a new security concept including a new security cell had to be created. The extended scope of delivery also included changes to the existing system after the robot cell:

• as-is analysis and transfer of the system functions and data from the old S5 to a new Siemens S7 controller,
• new control cabinets,
• new, advanced safety technology,
• various mechanical adjustments including repairs, where necessary,
• a complete new cabling and commissioning of the new plant.

The described project is an excellent example of the competencies of Münstermann in the field of automation.