Automation in Injection Moulding: Transforming Traditional Operations
Industrial automation, defined as the use of control systems and technology to manage production processes, has radically transformed the landscape of injection moulding. In essence, automation streamlines the manufacturing process, leading to increased throughput and reduced labour costs. One should not underestimate the value of automation in this field; it is not merely a trend but rather a pivotal element that equips companies to compete in today’s global market.
Consider the repetitive tasks involved in injection moulding, such as loading and unloading moulds, separating finished parts, or even the precision required in handling delicate or intricate components. Automation, through the use of programmable logic controllers (PLCs), industrial PCs, and human-machine interfaces (HMIs), serves to enhance these processes. This synergy optimises time efficiency, reduces manual errors, and increases production capacity, thereby positively impacting the bottom line of the manufacturing company.
The Advent of Robotics in Injection Moulding
While automation sets the stage for efficiency and precision, the introduction of robots into the injection moulding process takes these advantages a step further. Robots are typically used in two distinct areas of injection moulding: sprue pickers and full servo robots.
Sprue pickers, as the name suggests, are specifically designed to remove the sprue or any other waste material from the mould, thereby enhancing the cleanliness and maintenance of the machine. Full servo robots, on the other hand, are involved in more intricate tasks, such as the extraction and placement of moulded parts, assembly, packaging, and even quality control.
Robots, through their accuracy and consistency, not only mitigate the risks associated with manual handling but also bring about significant improvements in product quality and repeatability. By integrating robots into the production line, manufacturers can ensure that the process is tightly controlled, reducing variability and the chance of defects in the final products.
Types of Robots Employed in Injection Moulding
In injection moulding, several types of robots, each with unique capabilities and advantages, are employed to facilitate specific tasks. They range from Cartesian or gantry robots, known for their precision and speed, to articulated arm robots that excel in flexibility and reach.
Understanding Cartesian Robots in Injection Moulding
Cartesian robots, also referred to as linear or gantry robots, are one of the most commonly utilised robots in injection moulding applications. They operate within a three-axis Cartesian coordinate system (X, Y, and Z), which enables precise and swift linear movements. Cartesian robots are often prized for their high speed, accuracy, and relative ease of programming and control.
These robots are typically used for simple to complex pick-and-place applications, parts removal, and post-processing tasks such as assembly, decoration, and inspection. Given their ability to handle high payloads, they are also suitable for large part moulding operations.
Leading manufacturers, such as Wittmann Battenfeld and SEPRO Group, offer a range of Cartesian robots tailored for injection moulding, each designed to cater to varying production requirements and moulding machine sizes.
Advantages of Articulated Robots in Injection Moulding
For complex injection moulding tasks requiring superior flexibility and reach, articulated robots, also known as six-axis robots, offer an optimal solution. These robots have rotational joints that allow for movement in multiple directions, mimicking the human arm’s functionality. This characteristic enables them to easily navigate around obstacles and operate within confined spaces.
Articulated robots are used in tasks that involve a high degree of complexity and precision, such as intricate parts removal, insert moulding, in-mould labelling, and operations where parts need to be placed at unusual angles. Moreover, they can be deployed in the secondary operations that follow moulding, such as inspection, assembly, packaging, and palletising.
Renowned companies, such as KUKA and ABB, provide high-performance articulated robots that deliver enhanced precision, flexibility, and speed, thereby boosting the efficiency of the injection moulding process.
The Emergence of Collaborative Robots (Cobots) in Injection Moulding
In recent years, collaborative robots, or cobots, have gained considerable traction in the injection moulding industry. Unlike traditional robots, cobots are designed to work alongside human operators in a shared workspace, fostering a collaborative environment.
These robots are equipped with advanced safety features and sensors that allow them to detect human presence and adjust their speed or halt operations to prevent accidents. Consequently, they are ideal for tasks requiring human-robot collaboration, such as machine tending, quality inspection, or operations requiring manual intervention.
Cobots, provided by companies like Universal Robots and FANUC, offer the advantages of easy programming, versatility, and a compact footprint. By combining the strengths of humans and robots, cobots can significantly enhance flexibility and productivity in the injection moulding process.
Concluding Thoughts
Automation and robotics have undeniably revolutionised the injection moulding industry. From increasing productivity and improving product quality, to reducing labour costs and enhancing worker safety, the benefits are far-reaching. By understanding the capabilities of different types of robots and harnessing their potential, manufacturers can stay ahead in the competitive landscape, offering superior and cost-effective solutions to their clients.
