ABB Australia Value Provider Automation Innovation based in Keysborough Victoria has designed and engineered the new AiRC-1000, a machine that features ABB robots to clean anode rods used in aluminium production more intelligently.
Aluminium manufacturers are facing an unavoidable need to reduce energy costs and improve operational and production efficiencies. Currently, in-line automated brushes attempt to clean the rods' surface with inconsistent results; allowing contamination to build up and reduce the anode rod’s conductivity. On top of this, contact with the rods destroys the brushes causing a need for frequent replacement. This results in increased electricity usage and exorbitant operational costs. Automation Innovation’s AiRC-1000 machine is offering aluminium manufacturers a new, cost-effective, and progressive alternative by combining high powered laser cleaning technology and robotic automation, whilst facilitating optimum rod surface conductivity.
Laser manipulation is achieved with the ABB IRB 4600, a highly productive industrial robot optimised to increase production output demands. Thanks to its flexible design and high acceleration speeds, the IRB 4600 can reduce typical industry cycle times by up to 25%.
The laser cleaner in action 
Full machine view
The overhead conveyor input type of the AiRC-1000 can allow for a throughput of up to 500 anode rods per day* and the process ensures cleaning consistency and repeatability, complete with Industry 4.0 integration and reporting. It is estimated that the return on investment for this system is between 12 and 18 months.*
Manufacturers will also benefit from the elimination of premature wearing down of parts, no ongoing consumables, and no additional materials or chemicals required for a greener and safer preferred cleaning solution. Cost savings can also be experienced thanks to power usage reductions in the smelting process, and the convenience of the AiRC-1000’s ability to operate autonomously 24/7.
Automation Innovation is also gearing up to export the AiRC-1000 internationally.
ABB (ABBN: SIX Swiss Ex) is a leading global technology company that energizes the transformation of society and industry to achieve a more productive, sustainable future. By connecting software to its electrification, robotics, automation and motion portfolio, ABB pushes the boundaries of technology to drive performance to new levels. With a history of excellence stretching back more than 130 years, ABB’s success is driven by about 110,000 talented employees in over 100 countries. www.abb.com
ABB Robotics & Discrete Automation is a pioneer in robotics, machine automation and digital services, providing innovative solutions for a diverse range of industries, from automotive to electronics to logistics. As one of the world’s leading robotics and machine automation suppliers, we have shipped over 400,000 robot solutions. We help our customers of all sizes to increase productivity, flexibility and simplicity and to improve output quality. We support their transition towards the connected and collaborative factory of the future. ABB Robotics & Discrete Automation employs more than 10,000 people at over 100 locations in more than 53 countries. www.abb.com/robotics
*For an average sized plant.
