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Freedom251 › Blog › foundry

How to Choose Heat-Resistant Protection for Industrial Robots in Foundries

By Freedom251 Team · · 5 min read

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Choose robot protection by the hazards in the actual foundry process and the exact robot setup—not by a single temperature label. First map heat, sparks, hot particles, molten-metal splash, moisture and cleaning conditions; then match the cover or OEM foundry configuration to the robot’s model, equipment and movement. Require product-specific evidence for the exposure you expect.

Start by identifying the actual exposure

“Heat” can mean very different things to a robot cover. Radiant heat from a furnace, contact with a hot workpiece, sparks, hot solid particles and molten-metal splash are distinct hazards. Foundry environments may also expose equipment to dust, dirt, lubricant, moisture, steam or aggressive splashes. A cover claim for one does not establish protection from the others.

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Document the process before requesting a recommendation. Include where the heat comes from, its distance and orientation relative to the robot, whether exposure is continuous or intermittent, and how long the robot is exposed during each cycle. Note whether it can contact hot parts or receive sparks, scale or metal splash. Include cleaning methods and any moisture or steam exposure. Ask the supplier to assess the real cycle and exposure duration, not just the hottest nominal process temperature. EVOTEC describes radiant heat and hot-particle protection; ASP discusses foundry and thermal protection; ABB also describes foundry exposure and cleaning considerations in its Foundry Plus 2 brochure.

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Match the protection to the hazard and its evidence

A reflective surface may reflect part of radiant heat, but that alone does not show that a cover can withstand direct contact with hot metal or molten splash. EVOTEC describes non-flammable fabrics and often a reflective coating, with thread and connection choices dependent on fabric and process. Ask which layers and construction details address each hazard in your application.

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ASP describes fabric options, an M1 fire-rating claim, resistance to listed metals, and thermal claims that depend on exposure time. Treat each as a supplier-specific claim, not as a universal rating for robot covers. Request the current technical sheet for the exact material and construction, the test method and conditions behind each rating, and confirmation that those conditions represent your exposure. ASP’s product information separately states that thermal protection for forge production can be highly resistant to 200°C–600°C depending on exposure time, and that foundry fabric temperature resistance can range from 400°C–1600°C. These are two distinct supplier statements; neither range should be treated as a general operating limit or merged into one cover rating.

Make fit and movement part of the specification

A cover must fit the specific robot and installed equipment while protecting the areas exposed during the complete motion path. Give the supplier the robot make and model, tooling and mounted equipment, trajectory or motion envelope, heat-source position, and service requirements. ASP says its covers are custom-made for fitted equipment and trajectories. EVOTEC describes choosing connection methods to limit contaminant ingress and says rotary rings can improve freedom of movement while protecting the base in some applications.

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Check the proposed design around the wrist, joints, cables and base. Confirm that seams, joints and any rings or openings stay protective throughout the motion, do not snag or restrict movement, and leave required inspection and service points accessible. ASP’s cover information and EVOTEC’s radiant-heat cover information describe these application-specific design considerations.

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Compare an external cover with OEM foundry protection

Before adding an external cover, check whether a suitable foundry configuration is available for the robot itself. Compare both options against the same hazards, model, motion, cable and wrist exposure, cleaning process and service requirements. An OEM configuration may protect parts of the robot through sealing, coatings or protected components; it does not automatically cover every process-specific exposure.

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ABB Foundry Plus 2

ABB’s Foundry Plus 2 brochure describes improved sealing, corrosion-resistant coating, additional cable and electronics protection, optional cable guards, and IP67 compliance. It also says the system can withstand high-pressure steam washing. The brochure is dated November 2011, so verify current availability, exact model compatibility and specifications with ABB before relying on it. The same brochure gives an illustrative motor-failure example of €2,000–€2,500 in material and repair costs and 12–24 hours of unplanned downtime; those figures are not a current industry average, independently validated savings, or a return calculation for a heat cover. ABB Foundry Plus 2 brochure.

KUKA foundry configurations

KUKA describes foundry robot features including heat- and corrosion-resistant coating, an IP67 foundry wrist, sealing air, Viton seals and special covers for harsh conditions. These are product-family descriptions: check the exact model, application and current technical specifications with KUKA. KUKA foundry robots.

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Plan cleaning, inspection, repair and temperature management

Ask how the cover can be inspected, removed, cleaned, repaired and replaced, and how much production interruption each task requires. Verify that the cleaning method is compatible with the cover materials and construction. ASP describes reinforced seams and repairability; EVOTEC describes selecting process-specific joining methods to help prevent contaminants getting beneath the cover. ABB’s steam-washing claim applies to the cited Foundry Plus 2 system, not to arbitrary external covers.

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If internal robot temperatures may exceed the robot’s operating limits, discuss the measured conditions with both the cover supplier and robot OEM. ASP describes ventilation as an option, but its product information does not provide a universal sizing rule. Do not assume ventilation is needed—or sufficient—without considering measured internal temperature, robot limits and the cover design. ASP heat-protection information.

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Use a like-for-like selection checklist

Ask each supplier to respond to the same process specification. This makes external custom covers and OEM foundry configurations easier to compare without treating unlike temperature claims as equivalent.

  • Which hazards does the proposed configuration address: radiant heat, direct contact, sparks, hot particles, molten splash, dust, moisture, steam or cleaning chemicals?
  • Is it specified for the exact robot model, installed equipment and trajectory?
  • How are the base, wrist, joints and cables protected through the full motion?
  • What material, seams, threads, connections and other construction details are used?
  • What test method, exposure duration and conditions support each stated rating?
  • Will the cover preserve movement and provide practical access for inspection and service?
  • How is it cleaned, repaired and replaced, and what is the expected maintenance process?
  • Do measured internal temperatures and the robot maker’s limits call for ventilation or another temperature-management measure?

Supplier and OEM descriptions provide useful starting points, but the available information does not establish an independent comparison proving one cover or fabric is superior. No site-specific heat-flux profile, exposure-time profile or robot thermal limit is established here. Base the final selection on current technical documentation for the proposed product, the actual process exposure and the robot maker’s operating limits.

Check compatibility claims against the exact configuration

Yaskawa Europe’s ecosystem listing identifies EVOTEC’s EVO_heat as a compatible safety accessory for HC20DTP, HC10DTP Classic, HC10DTP, GP12 and AR1440 models, and lists Arc Welding and Handling applications in Europe. The listing repeats HC10DTP; confirm the exact model, configuration and current supply with the relevant supplier before specifying it. This regional listing is not evidence of compatibility with other robot models or foundry processes. Yaskawa Europe’s EVOTEC EVO_heat listing.

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Product prices and availability are accurate as of the date/time indicated and are subject to change. Any price and availability information displayed on Amazon at the time of purchase will apply.

foundryheat protectionindustrial robotsrobot coversRobotics

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