| Abstract Scope |
Aluminum cast shops rely on frequent sampling to support process control and quality assurance. Routine sample handling remains a necessary but labor-intensive activity in most facilities, requiring operators to repeatedly perform sampling, sample handling, identification, and laboratory dispatch tasks. This paper presents an automated sample management cell designed to automate the complete sample workflow, from casting through laboratory dispatch. The system combines robotic handling, machine vision inspection, controlled cooling, laser identification, automated sprue removal, and pneumatic transport within a compact, self-contained platform. The architecture provides complete sample traceability while reducing handling variability and operator exposure to hot metal environments.
At the core of the system, a robotic manipulator autonomously transfers and evaluates samples throughout the process using machine vision and automated decision-making. Non-conforming samples are automatically rejected, while accepted samples are processed and dispatched for laboratory analysis without operator intervention. The cell is integrated with an autonomous skimming robot that can also perform molten metal sampling through an automatic tool-change system, enabling seamless coordination between sample collection and downstream processing.
The resulting platform supports Industry 4.0 objectives by improving repeatability, increasing sample throughput, reducing safety risks, and enabling standardized quality control workflows. The paper presents the system architecture, automation strategy, machine vision methodology, and the expected impacts on cast shop productivity, safety, and metallurgical process control. |