In the past several years, EWI has successfully developed tele-manufacturing capabilities to remotely operate several fabrication processes. Our latest tele-task transformation is arc gouging. In a project supported by the Steel Founders Society of America (SFSA), EWI set out to automate specific manual foundry processes known for being difficult, dirty, and/or dangerous. Carbon arc gouging was selected because it is an especially nasty process that involves significant training, specialized worker PPE, and a lot of dust, vapor, and noise. In addition, gouging operator positions have been increasingly hard to fill, so it made sense to look into the development of an automation-assisted solution.
In late 2023, we reported on the demonstration of a new, remotely operated, arc gouging method. Following successful results, we launched the next phase of the project – creating a beta prototype system that could be set up, tested, and refined in an operating foundry.*
This spring, EWI installed our novel tele-operated arc gouging system at Ashland Foundry & Machining Works in Ashland, PA. Provided with an instructional manual and quick start guide, foundry employees were led through a training overview by the EWI developers. The prototype was put through the paces with Ashland’s gouging experts using the system and providing valuable feedback as we continue to streamline the technology and update it for the current and future workforce. Some key aspects being tested include the following:
- System durability under working foundry conditions
- A selection of different hand-held control device options
- Protection requirements for hardware
- Necessary safety add-ons
EWI and the Ashland project team have created a plan of functionality updates that will be applied to the tele-gouging system. SFSA continues to support the development of tele-controlled technologies as they advance the steel industry through innovative research.
If you are interested in bringing this capability into your facility or want to learn more about automating your manual processes, contact Connie LaMorte at [email protected].
* This research is sponsored by the DLA-Troop Support, Philadelphia, PA, and the Defense Logistics Agency Information Operations, J68, Research & Development, Ft. Belvoir, VA. The publication of this material does not constitute approval by the government of the findings or conclusion herein. Wide distribution or announcement of this material shall not be made without specific approval by the sponsoring government activity.