Design, initial modeling and preliminary tests of a hydraulic arm for removing slag when melting metal alloys

• Grant number: 24/16634-3
• Support Opportunities: Research Grants - Innovative Research in Small Business - PIPE
• Start date: July 01, 2025
• End date: March 31, 2026
• Field of knowledge: Engineering - Mechanical Engineering - Mechanical Engineering Design
• Principal Investigator: André Luis Carraro
• Grantee: André Luis Carraro
• Company: GUINDAUMEC SOLUCOES HIDRAULICAS LTDA
• CNAE: Fabricação de máquinas para a indústria metalúrgica, exceto máquinas-ferramenta
• City: Piracicaba
• Pesquisadores principais: Guilherme Correr ; Milton Luis Correr

Abstract

GUINDAUMEC is a leading company in the development and manufacture of hydraulic solutions, committed to technological innovation and operational excellence. Operating in the Brazilian metallurgy sector, one of the most prominent on the world stage, and within this sector the company operates in the foundry industry. This industry is known for its high risk of accidents and occupational diseases, due to the interaction between man x machine x product, which exposes workers to various hazards.Aiming to increase automation to improve the efficiency, quality and safety of processes, GUINDAUMEC proposes an innovative solution for the removal of slag in induction furnaces. Currently, this task is often performed manually in Brazil, especially in smaller facilities or where full automation is not feasible due to cost constraints or size of the operation. This project seeks to continuously improve processes in foundry units through automation, through an investigation that will be carried out in a number of foundry units.The objective is to understand the challenges related to the operation of induction furnaces and manual slag removal, using action research as a methodology, which will allow for a participatory and interactive analysis between the project researchers and the employees of the foundry units. Initially, direct observations of the operational processes will be carried out focusing on the induction furnaces, analysis of the manual slag removal operation, working and safety conditions, and identification of technical and operational challenges. These observations and interviews, combined with quantitative data such as operating time, frequency of failures and accidents, will provide an understanding of the existing operations and the employees' perceptions of current removal solutions. Based on the data collected, automation proposals will be developed using CAD (Computer-Aided Design) and SolidWorks software to design all subassemblies of the robotic system. Then, modeling and simulation of the designs in the chosen software will allow 3D visualization and validation of the proposed system, ensuring that the project meets performance, safety and usability criteria. Once the simulations have been validated, a functional prototype will be built, following the models and simulations developed, which will then be subjected to preliminary testing at GUINDAUMEC to validate its performance and identify possible areas for improvement. Finally, all activities will be documented in technical and accountability reports, as required by the PIPE Phase 1 Program. (AU)