Pouring molten aluminium: manipulator with ladle and ZH90 lifting axis with crucible
Molten aluminium can be moved safely, in exact doses and without swinging from the melting furnace to the mold with a lifting aid. Zeilhofer Handhabungstechnik builds two solutions for this: a manipulator with ladle that doses the amount automatically, and the ZH90 lifting axis with an integrated crucible.
Solution 1: manipulator with ladle
With this manipulator, operators pick up the right amount of molten aluminium safely and pour it into the sand mold:
The operator moves the lifting aid to the melting furnace containing the molten aluminium.
The manipulator lowers automatically and fills the special ladle with exactly the required amount.
The operator guides the manipulator to the sand mold without swinging.
The molten aluminium is poured precisely into the sprue of the sand mold.
Like all Zeilhofer systems, the manipulator is individually configured and manufactured to suit the furnace, molds and workstation.
Solution 2: ZH90 lifting axis with crucible
In aluminium die casting, molten aluminium is filled from the melting furnace directly into the crucible attached to the ZH90 lifting axis. The operators then move the lifting axis to the individual casting stations and molds and use the joystick to pour the exact amount into the mold.
Because the crucible sits directly on the lifting axis, it cannot swing as it would on a chain hoist or crane. This protects operators from molten aluminium and relieves them physically (video of the ZH90 lifting axis pouring).
Manipulator or lifting axis: which solution fits?
Manipulator with ladle: automatic dosing directly at the furnace, ideal for sand casting with changing mold positions within the working radius.
ZH90 lifting axis with crucible: serves several casting stations in sequence, high loads up to 1,200 kg, mounted on ceiling or floor or travelling on rails.
Other systems are compared in the guide choosing a lifting axis. Technical data on the ZH90 lifting axis.
Benefits compared with crane and chain hoist
Swing-free guidance of ladle and crucible, no sloshing and fewer splashes.
Exact dosing and therefore consistent casting quality.
Distance from heat and molten metal, protection by heat shielding.
Ergonomic work: the lifting aid carries the weight, the operator only guides.
Heat-resistant components up to 600 °C in the standard range.
Casting processes and design
The solutions shown were implemented for sand casting and aluminium die casting. For other processes such as permanent mold casting, Zeilhofer designs ladle, crucible and lifting aid individually. For the design we need fill quantity and weight, position of furnace and molds, stroke and cycle time.
More applications: lifting aids for foundries and the guide handling forgings and castings.
Frequently asked questions about pouring with a lifting aid
Can a manipulator pour molten aluminium?
Yes. A Zeilhofer manipulator with a ladle picks up molten aluminium from the melting furnace and pours it into the mold without swinging. The operator only guides the lifting aid, keeping weight and heat at a distance.
How is the amount of molten aluminium dosed?
With the ladle manipulator, the lifting aid lowers automatically and fills the ladle with exactly the required amount. With the ZH90 lifting axis and crucible, the operator controls the amount via joystick when pouring into the mold.
What is the difference between ladle and crucible?
The ladle on the manipulator scoops a dosed amount directly from the melting furnace. The crucible on the ZH90 lifting axis is filled at the furnace and then moved to several casting stations, for example in aluminium die casting.
Why not pour with a crane or chain hoist?
On a crane or chain hoist the crucible swings. With molten aluminium this leads to splashes and inaccurate pouring. Manipulators and lifting axes guide the ladle or crucible rigidly and without swinging.
Which loads are possible?
Zeilhofer articulated arm manipulators carry up to 800 kg, the ZH90 lifting axis up to 1,200 kg. The design depends on crucible size, fill quantity, working radius and stroke.
Can the systems withstand the heat?
Zeilhofer uses heat-resistant components up to 600 °C and high-temperature pads for 200 to 400 °C. Shielding against radiant heat additionally protects the operators.
What does a casting manipulator cost?
That depends on load, fixture and control. Simple manipulators start at around EUR 10,000, complex lifting axis solutions reach up to around EUR 150,000, excluding installation and commissioning.
Zeilhofer Handhabungstechnik, Holzkirchen, Germany: manipulators up to 800 kg and lifting axes up to 1,200 kg, designed and manufactured in Germany.
