Charging Manipulators for Forging Operations — Adhvika Forgetech Pvt. Ltd.
Efficient material handling is the backbone of any high-performance forging operation. At Adhvika Forgetech Pvt. Ltd., we specialize in manufacturing and supplying a comprehensive range of charging manipulators designed to load, transport, and position hot and cold billets, ingots, discs, and rings safely and precisely across a variety of forging processes.
Our manipulators operate in diverse forging environments — from open-die forging plants, ring mills, blooming mills, to fully automated forging lines — helping you increase production throughput, reduce labor intensity, and improve forging quality.
Our Charging Manipulator Categories
Rail-Bound Charging Manipulators
These manipulators move along fixed rails installed on the forging floor, offering smooth and precise horizontal travel. They excel in repetitive, high-load charging operations for heavy billets and large forged components.
Key movements include manipulator trolleys moving along rails, rotary heads, clamp rod extension/retraction, lifting/lowering, and clamp rotation.
Mobile / Forklift-Mounted Charging Manipulators
Designed for versatility and flexibility, these manipulators can move freely within the forging shop without relying on fixed rails. Their mobility lets you handle a range of billet sizes and shapes, and
they are especially valuable in smaller or multi-purpose plants.
CNC Charging Manipulators
Equipped with advanced hydraulic systems and digital control technology, CNC manipulators offer fully programmable, semi-automatic, or manual operation modes. They ensure precision clamping and positioning with repeatability to support Industry 4.0 and automated forging processes.
Frame-Type Charging Manipulators
These manipulators feature a robust structural frame with adaptable clamp and fork options to handle different forging workpieces. Their mechanical-hydraulic hybrid system allows for smooth, precise handling of billets, discs, and rings during the forging cycle.
Custom Solutions
Our engineering team develops specialized charging manipulators tailored to your unique forging process, capacity, and automation needs. We handle everything from the smallest forging shops to large industrial plants requiring highly integrated charging automation.
Technical Specifications and Features
Capacity Range: Customizable from small-scale 3-ton units to heavy-duty 50+ ton manipulators
Motion Functions:
Manipulator horizontal travel (railbound or free movement)
Clamp rod extension and retraction for gripping
Clamp lifting and lowering for furnace loading/unloading
Clamp/tong rotation with 360° swivel for optimal workpiece positioning
Optional upper structure rotation and tilting in complex models
Drive System:
Mechanical-hydraulic hybrid for balanced power and control
Fully hydraulic models available for smooth continuous motions
Electrical actuators and programmable logic controllers (PLC) for CNC-enabled units
Control Modes:
Manual operation with joystick/pedal controls
Semi-automatic sequencing for repeatability
Fully automatic integration with forging presses and ring mills for synchronized workflow
Safety and Reliability:
High-temperature resistant construction
Robust clamp and tong designs to safely hold heated billets
Fail-safe hydraulic systems and emergency stop controls
Operator-friendly interfaces and remote control options
Precision:
Positioning accuracy up to ±0.5° rotation and millimeter-level travel precision
Smooth travel with backlash-free mechanisms
Integration-ready for digital forging process control and diagnostics
Benefits of Adhvika Forgetech Charging Manipulators
Boost efficiency and output: Fast, precise billet handling reduces furnace idle and press downtime, leading to higher throughput.
Reduce labor costs and risks: Automated handling minimizes operator exposure to extreme heat and heavy loads.
Improve forging quality: Secure and repeatable clamping and positioning ensure consistency in forging shapes and mechanical properties.
Flexible integration: Our manipulators can be customized to suit manual or fully automated forging lines.
Long-term reliability: Designed and manufactured using premium materials and components for maximum uptime and low maintenance.
Applications
Our charging manipulators are widely used in the steel and metal forging industries, including:
Open-die forging presses and hammers
Ring rolling mills for aviation and automotive rings
Blooming mills for slab handling
Custom forging workshops requiring flexible billet handling solutions
Integrated automated forging production lines
Customer Success
Adhvika Forgetech’s charging manipulators are trusted across India and export markets like China and Russia. Our clients report significant improvements in productivity, safety, and forging quality after deploying our manipulators in their production lines.
Get a Tailored Charging Manipulator Solution
Whether you need a rail-bound system for heavy, repetitive charging or a CNC-enabled manipulator for cutting-edge automation, Adhvika Forgetech can design the perfect manipulator to fit your plant layout, workpiece dimensions, forging press, and production targets.
Contact us today for a consultation, product demo, or custom quote. Let us help you enhance your forging operations and stay ahead in a competitive market.
