Draft:Forging manipulator

• Comment: This is not obviously AI, but assertions such as "AI-based monitoring enables adaptive adjustment of machine parameters in real time" are fuzzy and unsupported, as the source this is referenced to doesn't even mention AI adjusting parameters. The plaintext list under "Functionality" does not inspire confidence, as well as how this article was created in one edit. Somepinkdude (talk) 18:13, 20 December 2025 (UTC)

---

A forging manipulator is a vehicle used in open-die forging to move the workpiece between the tool saddles. In some cases, the forging manipulator is also used to transport the workpiece between the heating furnace and the forge. There are both freely movable and rail-bound designs.

History

The first forging manipulator was presumably built in 1897 by Vickers in the United States and was powered by a steam engine. The first successful version was produced in 1925 by the company of John Baker and Henry Bessemer, Baker & Bessemer Co. in Kilnhurst (South Yorkshire).

From the 1930s and 1940s onward, development accelerated. In 1936, the German company Dango & Dienenthal built the first freely movable (mobile) forging manipulator for the domestic industry. In the 1950s, rail-bound manipulators followed, travelling along track systems next to the press and capable of handling even heavier workpieces. Early machines were predominantly mechanical. In the 1960s and 1970s hydraulic and partly hybrid drive systems became established and allowed more compact designs and faster movements.

Up to the 1980s, demand for forging manipulators grew with the expansion of the heavy industries. Designs were continually improved, and the equipment became a key component of modern open-die forging shops worldwide. By the mid-1990s, the technology of large forging manipulators was considered mature: in combination with the then largest open-die presses (approximately 30,000 kN), manipulators significantly increased forging efficiency. Record performance figures were achieved in the 21st century – for example, in 2007 Dango & Dienenthal built a rail-bound manipulator with 2,550 kN load capacity and 7,500 kN·m tipping moment, then the largest of its kind worldwide.

Types

Forging manipulators are generally classified as either freely movable (mobile) or fixed/rail-bound systems. Mobile forging manipulators are self-propelled vehicles on wheels or heavy-duty tires that can move freely within the forge hall. They often feature a central rear axle or a three-wheel configuration for high manoeuvrability, allowing tight turning. An operator sits in a protective cab close to the tong unit with good visibility of the workpiece, though remote control from a safe operator station is also possible. Mobile manipulators typically transport the glowing workpiece from the furnace to the press and handle it during Forging operations; they must move quickly to minimize heat loss.

Power supply is provided either via cable (electric traction) or via an onboard combustion engine (diesel/gas) for driving, while the working functions are hydraulic. Stationary or rail-bound manipulators, by contrast, are tied to a fixed track or installed directly on the press. They travel along rails next to the forging press or hammer and move synchronously with the forming process. These types are typically larger and, due to their guided motion, suited for extreme loads and high positioning accuracy.

Drive technology also serves as a distinguishing feature. Earlier designs used mechanical gear systems or hybrid hydraulic–mechanical systems. Today, forging manipulators almost universally employ hydraulic drives for the main movements, providing the required forces and synchronous motion. Modern machines use electronically controlled hydraulics (via PLC), for example with proportional valve technology for smooth and precise motion even with large workpieces. Depending on the model, the energy source is an electric or diesel motor; electrically powered versions often employ a cable reel for power supply.

Functionality

A forging manipulator acts as an extended arm of the smith or forging press. Its tong unit – usually a hydraulically actuated gripper with interchangeable jaw inserts – can securely grasp and hold glowing blocks, ingots or pre-material. Modern systems allow integration with the press control so that the manipulator automatically follows each press stroke. Control can be manual or automated. In many open-die forges, an operator sits in the cab or stands at a console, using joysticks or levers to actuate the hydraulic valves proportionally. Modern cabins are air-conditioned, sound-insulated and equipped with cameras/monitors for safety and ergonomics. Remote operation is often used for hazardous forging processes (e.g. titanium with spark or explosion risks).

Highly automated forging lines use CNC control, enabling autonomous movement after each stroke and automated angle/position adjustments, particularly in series production for die forging.

Typical degrees of freedom include: (1) linear movement of the vehicle or carriage, (2) raising/lowering of the tong unit, (3) possible telescoping or lateral shifting, (4) rotation of the gripper head about the vertical axis, (5) rotation of the workpiece about its longitudinal axis, and (6) opening/closing of the tongs. Large manipulators therefore provide up to six controllable axes.

Sensors such as linear encoders, pressure sensors and rotary encoders allow continuous monitoring of the workpiece position. Modern hydraulics and electronics enable centimetre- or millimetre-level accuracy despite the large masses involved. This makes precise contour forging and thin-walled components feasible.

If workpieces approach the manipulator’s load limit, a shop crane may support the load while the manipulator provides alignment. Safety equipment includes heat shields, cooling systems and emergency-stop functions. Mobile manipulators use collision sensors and warning systems, sometimes projecting a blue warning spot on the floor when a person approaches.

Technical specifications

Forging manipulators vary widely in size, from smaller units handling a few tonnes to machines for hundreds of tonnes. Load capacities range from under 100 kN (≈10 t workpiece mass) for compact models to more than 2,500 kN for the largest units.

Vecchiato Officine Meccaniche Srl (Italy) offers mobile manipulators between 2 t and 50 t, while Dango & Dienenthal introduced a 1,500 kN (≈150 t) mobile heavy-duty manipulator in 2011. Machine weight can range from tens to several hundred tonnes.

Large manipulators typically feature five to six degrees of freedom, enabling multi-sided forging. Besides load capacity, manufacturers specify the tipping moment (in kN·m). State-of-the-art manipulators reach several thousand kN·m, with leading models at roughly 7,500 kN·m.

Large manipulators rely almost exclusively on hydraulic actuators for gripping, lifting and motion, with PLC or CNC control and modes from manual to fully automatic operation. Equipment may include swivelling operator cabins, camera systems and telemetry for remote condition monitoring. Grippers are modular and adaptable to different geometries.

Recent developments

Current developments are driven by automation, digitalisation and increased performance. Fully automated forging lines integrate manipulators with industrial robots and intelligent sensors, reducing physical strain and increasing productivity by over 30&nbsp%.

An important research field is the use of artificial intelligence (AI) and digital twins. AI-based monitoring enables adaptive adjustment of machine parameters in real time, including predictive maintenance. Camera-based and sensor-supported systems can detect deformation on the hot workpiece and adjust position automatically.

Under the Industry 4.0 paradigm, manipulators are increasingly integrated into higher-level data and control systems. Modern machines transmit operational data to central databases or cloud platforms for analysis. One example is “D&D Connect”, an online portal for remote monitoring, maintenance planning and spare-parts management. AR technologies are also entering the field.

Sensor technology and safety features are advancing, including autonomous or semi-autonomous driving within the forge hall. Energy-efficient technologies such as electro-hydraulic drives, energy-recovery systems and variable-speed pump drives reduce consumption.

Ever-larger components, for example for the nuclear industry or shipbuilding, require manipulators beyond the 300-tonne class. Research focuses on controlling huge masses with multi-axis synchronisation and maintaining precision despite high inertia.

Manufacturers and distribution

Forging manipulators are built by specialised engineering firms and, in some cases, by forging-press manufacturers. German companies play a significant role: Dango & Dienenthal (Siegen) has been a pioneer since the 1930s and has built several record-breaking machines. Another established manufacturer is GLAMA (Gladbeck), producing manipulation and handling equipment since 1961. Additional manufacturers exist in Italy, France, the United Kingdom, Russia, China and India.

The United States and Japan have traditionally imported manipulators or produced them under licence. Recently, Chinese manufacturers have advanced technologically, reducing reliance on imports and emerging as exporters.

Forging manipulators are used wherever heavy open-die forgings are produced, such as turbine shafts, generator rotors, ship crankshafts, large rolls, pressure-vessel components or aircraft landing-gear parts. Only with manipulators can such massive workpieces be handled with the required precision. Worldwide, the number of extreme heavy-forging presses (≈10,000-tonne class) is estimated at around 30.

Accordingly, the distribution of the largest manipulators is limited: typically, each site operating such a press uses one or two specialised manipulators of similar capacity. Medium-sized forges commonly employ smaller manipulators (often 5–50 t). In technical literature, large manipulators are considered strategic key equipment in heavy forming technology.

References

This page will be placed in the following categories if it is moved to the article namespace.

Categories:

• Industrial machinery
• Metalworking tools
• Machine tools
• Hydraulic machinery