NP Germany’s turnkey system around a vertical Arburg injection molding machine takes up a quarter of the production hall.

Benedikt Niglis, head of project (left), and Plant Manager Mario von der Heyde are more than proud of their complex turnkey system

16:9

NP Germany: Extraordinary Turnkey System for Automotive Products

Spritzgießen

Kunststoffverarbeitung: Verfahren

Inspektionssysteme

Fertigungsautomation

Bildverarbeitung

Handling, Handhabungstechnik

Automatisierungstechnik

Linearroboter für die Kunststoffverarbeitung

Knickarmroboter

Montagetechnik

Industrieroboter

Hybrid-Spritzgießen (Metall / Kunststoff)

Qualitätssicherung Kunststoff

Qualitätssicherung

Dance of the Robots

At Fakuma 2021, Engel is expanding its product range of intelligent assistance systems. The new iQ motion control allows Engel viper series linear robots a reliable early start combined with fully automatically optimized motion planning. Users benefit twofold: from a time-saving in teach-in and shorter production cycles.

iQ motion control operates with automatically optimized motion planning

Folientechnik (IMD, IML, FIM, u.a.)

Messe Fakuma

kunststoffe-international.com

Spritzgießmaschinen

Kunststoffverarbeitung: Maschinen und Komponenten

Medizintechnik

Kreislaufwirtschaft

Optimized Motion Planning for Shorter Cycle Times

The aim of the project was clear: a highly automated turnkey system must replace several decentralized, operator-guided machines in order to be able to mass produce enclosures for a vacuum sensor with three inserted pins in a way that is smooth, automated and therefore faster than before in large-scale production, and error-free. The plastics processor Goerlich chose the machine manufacturer Arburg as a partner in its goal of achieving greater production efficiency.

All upstream process steps are integrated in a very small space: after the pins have been  punched out (right), a Scara robot places them in the correct position on a loading plate (left) so that the Multilift V robotic system can pick up 24 pins and insert them into the mold

At Goerlich, a Turnkey Plant Replaces Two Machines with a Vertical Clamping Unit

Automatisierungszellen

Spritzgießwerkzeuge

Werkzeuge für die Kunststoffverarbeitung

A Machine Strategy with  Extra Automation

iQ motion control from Engel now allows reliable early start combined with fully automatically optimized motion planning. The assistance system has been part of the standard kit of all new Engel viper-type linear robots since October 2021.

If the robot travels into the mold area already during the mold opening movement, this can shorten the cycle time. The effect is particularly large in the case of parts with long cores, such as boxes

iQ Motion Control Brings the Injection-Molding Machine and Robot Closer together

Steuerungen (Hardware und Software)

Industrie 4.0 für die Kunststoffverarbeitung

Industrie 4.0

A Production Cell with Fluid Movements

Once again, the K 2019 in Düsseldorf, Germany, lived up to its claim to be the leading trade show for plastics technology. At least in the field of injection molding, there were exciting global innovations to see – if you looked closely.

Fig. 1. Smart Operation – the machine is operated with only four buttons (© KraussMaffei)

Injection Molding Trends at K 2019

Schaumspritzgießen

Smart Factory

Energieeffizienz

Mikrospritzgießen

Mehrkomponenten-Spritzgießen

Spritzgießmaschinen, allgemein

Fließpressen

Handling, Handhabungstechnik für die spanende Fertigung

Spritzgieß-Sonderverfahren

Spritzgießsimulation

Software

Simulation

Elastomer-Spritzgießen

Montage-Spritzgießen

Co-Injektion (Barriere-/Sandwich-Spritzgießen)

Ressourcenmanagement

Produktion

Technical Excellence thanks  to Digital Assistance

“At our trade show presentation this year, we are concentrating on the automation and digitalization of our injection-molding machines,” says Alfred Schiffer, marketing partner at Dr. Boy GmbH & Co. KG, explaining the activities planned for Fakuma. Three of the four applications at its own tradeshow booth – four more can be seen at its partners – are equipped with Dr. Boy’s own LR 5 linear handling unit.

On the Boy 35 E, the LR 5 compact telescopic handling system is use for a medical LSR application

kunststoffe.de

Individual Automation and Digitalization

In injection molding, the component weight reflects the process consistency and the component quality. Components are therefore often weighed manually after production or automatically placed on a scale and picked up again. Engel has now developed a high-precision load cell for inline weight measurement that can be integrated directly between the rotary axes and the end-of-arm tooling of a linear robot.

Thanks to the new development, the component weight can be recorded inline

Weight Measuring System Directly on the Robot Ensures Process Quality

Automatisierungskomponenten

Wiege- und Dosiersysteme

Logistik

Verpackungstechnik

Weighing without Time Overhead

The new, 232 m2 sales and service center in Milton Keynes, Buckinghamshire, unites robot sales, service, parts, and robot-commissioning activities under one roof.

The new sales and service center located in Milton Keynes, Buckinghamshire, England

Sepro UK to Open New Robot Sales and Service Center

The introduction of fiber direct compounding at deller plastics Uwe Braselmann was driven by tangible economic advantages. The plastics processor uses the lightweight construction process for manufacturing cable drive housings for operating electric power windows in car doors.

The injection molding machine Allrounder 630 S is equipped with an 8-cavity hot runner mold. The even distribution of the fibers is confirmed by an incineration test

deller plastics Uses Competitive Advantages of Fiber Direct Compounding

Faserverarbeitung

Verbundwerkstoffe / Werkstoffverbunde

Kunststoff Werkstoffe

Lightweight Components  from the Roll

Pipette tips are small and relatively simple components that are now in high demand. One might think  producing large quantities of these products is a simple task. It is not. The requested high quality can only be reached by using complex automation. To meet these challenging requirements, MA micro automation has developed a modular solution: Centauri IVD.

The Centauri IVD production system can be adapted to meet specific pipette tip manufacturing requirements.

Automated High Volume Consumables Production

Medizinprodukte

Prozessautomation

From Tool to Blister

Injection, holding pressure, cooling phase – injection molding is a sequential process with individual steps that are usually optimized. Therefore, they offer little more potential for improving the cycle time. But what about the automation system?

With the synchronous motion function, the gripper of the robot starts faster, saving valuable cycle time.

Lucrative Early Start

Multiaxialroboter für die Kunststoffverarbeitung

Synchronous Motion Shortens Demolding Time up to 35 %

The diverse nature of industries and their requirements is something that suppliers of automation solutions also have to take into account. ''Adapted automation'' is the magic word, because widely ranging batch sizes, an increasing number of product variants and short product lifecycles typify many markets today. Plans for attractive, innovative universal solutions are hidden away in many drawers. Now is the time to pull these plans out and make them a reality. 

Handhabungsroboter

Industry in a State of Flux: Batch Size Is Everything 

Compared with 2010, the year of the last K fair, sales of robot systems doubled. By the end of 2013 the French supplier of robots and automation systems for plastics injection molding expects to sell more than 1,500 units. 

Sepro Robotique: Automation with Growth Spurt 

Beck Automation invented a new system to label plastics parts that is pending patent approval. Its special twist is the option of using a reduced opening stroke on the injection molding machine. For this purpose, the parts are rearranged in the mold after demolding. The process was introduced to the public at the U.S. plastics trade show NPE at the end of March, reducing the cycle times and costs of the production process, and stepping up output quantities for the packaging industry.  

Sophisticated Solution from Beck Automation Reduces Opening Stroke for IML Applications 

Rearrangement in the Mold 

At present, two automation trends are in evidence among plastics processing companies: On the one hand, the complexity of systems is increasing, while on the other, customers are seeking flexible solutions owing to ever faster product changes, increasing version diversity and, consequently, ever smaller unit volumes per order, down to one-off parts. This means, for example, that high-volume products can be individualized as one-off parts in a flexibly automated, digitally integrated production system by combining injection molding, generative production and "Industry 4.0" technologies. 

Automated Production Makes It Possible to Increase Part Quality, Process Reliability and the Productivity and the Flexibility of the Production Processes 

Mensch-Maschine-Interface

Greifer

Additive Fertigung

Systemperipherie

Optische Mess- und Prüftechnik

Digital Integration – Flexibly Automated Plastics Processing 

As an all-inclusive injection molding supplier, the Wittmann Group will also use the Fakuma to showcase its latest innovations in automation and peripherals. In 2019, the Sonic range of robots replaced the high-speed UHS series robots. Sonic robots now come with a new design and are fitted with the latest R9 robot control system.

As an all-inclusive injection molding supplier, the Wittmann Group will also use the Fakuma to showcase its latest innovations in automation and peripherals. In 2019, the Sonic range of robots replaced the high-speed UHS series robots. Sonic robots now come with a new design and are fitted with the latest R9 robot control system. In addition to the currently available machines for clamping forces from 1500 up to 5000 kN comes a new version for clamping forces of 500  kN upwards.

Contrary to the larger versions, the Sonic 108 is equipped with a fixed demolding axis, which has proved extremely advantageous for small injection molding machines. Small overhangs and a compact control cabinet simplify the CE-compliant enclosure of the automation cell. During the active demolding stroke movement beyond the mold space, no axis elements are moved towards the injection unit, which greatly simplifies the enclosure especially in the area behind the machine’s fixed clamping plate.

The Sonic 108 has been optimized for fast parts removal in packaging and pick-and-place applications. It is designed for cycle times below 4 s, with In/Out times less than 0.9 s. Although the drive system for this kind of high-speed removal has been completely revised, the robot is still able to handle payloads up to 2 kg.

The familiar Wittmann functions, such as iVac vacuum control with blow-off function, axis activation, SmartRemoval, and digital visualization of the axis movements are part of the appliance’s standard equipment. “Insider” use is also possible – in this case, the parts are deposited inside the injection molder’s protective housing. For the market launch at the Fakuma 2021, horizontal strokes of up to 1500 mm and vertical strokes of up to 1000 mm will be available.

Available since the middle of this year is the upgraded WX153 robot. According to Wittmann, it is the ideal automation solution for injection molding applications on machines with medium to high clamping forces (5000 to 13,000 kN).

Based on a cartesian axis structure, the system features a mobile X-axis that serves for demolding. With the WX153, horizontal strokes up to 18 m and vertical strokes up to 2600  mm are possible. For parts removal, an X-stroke up to 1400 mm is available. This 1400 mm demolding stroke has a maximum reach of about 1790  mm. The term “reach” designates the maximum distance between the horizontal axis and the mounting plate of the swivel axis at the lower end of the vertical axis. Reach is an essential parameter for the layout of robot systems.

Internal tubing and/or wiring in the vertical Y-tube, easily accessible lubrication points and the integrated control cabinet at the rear of the horizontal carrier are part of the WX153 robot’s standard equipment. Regardless of the number of additional axes selected, the control cabinet always maintains its original dimensions.

Three additional axes can be fitted per robot at the end of their vertical axe to operate the removal gripper. Moreover, Wittmann is also able to build tandem robot solutions, i. e. two traversing units acting on the main carrier. Even in these cases, an additional control cabinet is not necessary, so that the space provided for it beside the injection molding machine can be used for other peripherals other than automation equipment.

Even when using three additional axes, various optimizations permit the WX153 to operate with a gripper weighing more than 20 kg. Compared to the previous device concept, this corresponds to a possible weight increase of more than 30  %.

Wittmann Robot Systeme GmbH  

https://www.wittmann-robot.de

Wittmann Technology GmbH  

https://www.wittmann-group.com/

The Sonic 108 is optimized for fast parts removal in packaging and “pick & place” applications

The graphic illustrates the difference between reach and X-stroke; here for the WX153

2021-09-25 Automation Wittmann

issue 03/2022

issue 02/2022

issue 01/2022

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