Injection Molding and Linear Servo Robots
The Benefits of Linear Servo Robots…
XYZABC
Flexibility
Speed
Capability
Space Savings
Simplicity
Cost Effectiveness
Injection Molding and Linear Servo Robots
All Robots share the same justification premise: To reduce costs for the
manufacturer.
Cost reduction examples:
„ Direct labor savings
„ Quality improvement
„ Scrap reduction
„ Cycle time reductions
„ Value added operation
„ Safety improvement
But linear servo robots are unique in the world of robots as they are
designed and built specifically for Injection Molding. The following are
examples of Why linear servo robots are unique and How they benefit
the injection molder.
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
Mechanical Re-Orientation Flexibility
Flexibility…mechanical
The flexibility of the linear robot
traverse beam for re-orientation
allows molders to adapt from
application to application quickly
and easily on any side of the
molding machine.
From Operator side and Rear side
discharge to T-Beam and LongitudinalMount
Rear
Operator
T-Beam
Longitudinal
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
Mechanical Re-Orientation Flexibility
Flexibility…and safety
Uniquely, Linear servo robots can handle
parts on the operator side of the
molding machine w/o removing
safety gates.
Floor mounted type robots require rear
entry with safety gate removal; front
gate entry is not an option. But, floor
mounted robots could be pedestal
mounted from above or a 7th axis
linear beam option could facilitate
operator side work cell orientation.
Picking parts from the mold and placing to the
operator side is one of several standard linear
configurations
Operator side parts
handling
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
Great use of space and quality control
Flexibility…
T-Beam
The linear servo robot can
handle two sides of the
molding press within each
molding cycle by using a
standard T-Beam
configuration w/o the need
and purchase of additional
robots, servo axis or beams.
.
This linear configuration has excellent
utility for molders…saving cost and
complication.
Separate good product from rejects
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
E
Flexibility…reach
Linear robots have the advantage of
long reach and thus they are well
designed to place parts at the
clamp end of the molding
machine.
Another benefit: Clamp end parts
discharging saves space but also
allows a value stream of finished
product to flow down the main
aisle when molding machines are
aligned…a “trunk line” formation.
Clamp-end parts release
Create a value stream flow
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
Only 3 axis are needed for a 3-D work envelope
Flexibility…
Beware of “Over-Buying” the idea of
Flexibility
Work Envelope
With linear Servo Robots, molders do not have to
purchase more axis of motion than they need
to de-mold parts or perform secondary
operations….because…
3 Servo axis of motion is all that is needed to get
to any point in space (as shown) within it’s
work envelope. 4 or more axis is only needed
for more complex movements. Linear robots
do offer up to 10 axis of servo control if
needed.
Also note that the molding cycle governs how
much flexible value added work can be done
to demolded parts therefore if cycles are short
than over-buying flexibility is more apparent.
.
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
> Speed = > ROI
Speed…the Top Entry
If Speed is what a molder needs
then linear servo robots are the
tool for the job…whether it is a
high speed top entry or a high
speed side entry, no robot is
faster.
With it’s narrow profile, simple unknuckled take-out motion,
daylights stay narrow and cycle
times short. Only 1 or 2 axis of
motion are needed.
Speed increases Output
and increased Output
improves ROI
Top Entry
High Speed
Linear Robot
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
> Speed
The benefit of speed and simplicity
of 2-3 linear axis.
.2s take-out times………………..
For light weight low or high
cavitation thin walled parts, the
linear side entry can extract
parts in less than a second in
daylights under four inches.
> ROI
.
Speed…the Side Entry
Linear side entry robots are built
with one thing in mind… Speed.
..for fast molding cycles.
=
Show Movie Clip of a
W7X5HS side entry
Scara-robot here
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
High Speed IML: Stack mold label loading and
part removal
Speed…meets capability
IML: In Mold Labeling
Now built for more Capability
and Payload handling,
linear side entry robots
handle IML mold
applications very effectively.
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
Linear motion combined with articulated motion
Capability…
Linear robots are more capable than
ever. The linear robot now offers
A/C articulated servo wrists for
the most demanding de-molding
and value added applications.
Now linear robots offer the benefits
of both linear and 6 axis robots:
… long reach and the articulated
wrist.
Best of both worlds
Articulated A
and B servo
wrist axis
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
Capability…secondary operations
Secondary operations
„ Degating
„ Sorting
„ Insert loading
„ Tote / Box loading
„ Palletizing
„ Integration for labeling, serial
coding, bagging etc.
Systems Integration…………………..
Linear robots are more capable than ever.
..Why?…The linear robot offers CNC
based controllers combined with easy
programming to handle very
demanding value added processes for
the injection molder.
Metal Insert Loading
H
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
Multi-Operator interfaces
Capability…in control
They combine the intuitiveness of color
graphics yet have full CNC capability.
The pendant is not just focused on axis
control but also offers useful operator
and work cell information…
Controller Capability ……………..
Linear servo robots have color high
resolution control pendants that do
much more than just axis control.
A
Built-In Operation Manuals
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
Pre-mold
Show
pic /one robot serving
Overmolding
2 machines
Capability…special applications
Multi-mold structural foam machines
and family molds are also easily
handled.
Dual robot, single traverse beam:
Z+Z+X+X+Y+Y plus two C
posture axis (8 total axis of
movement control)
Linear Servo robots are not
limited to 3 servo axis of
movement!
Capability above and beyond…………..
Linear control capability and multi
axis capability handles Pre-mold
and Over-mold applications well.
Great
for
Show pic of 743SO
robot
Structural Foam
Demolding
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
Two Main Arms for Demolding
Three Plate Molds
Capability…3 plate molds
Stack mold de-molding is not
so simple with other types
of robots.
Stack molds and 3 plate molds…
Also…Linear robots are well
designed to handle Stack
molds and 3 Plate molds.
Show pic 744D
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
Capability…and constants
With linear servo robots speed and payload
is not a variable to be re-calculated
from application to application…i.e.
payload handling does not decrease
with reach or speed increases.
Linear robots: the payload handling is
the payload handling…simple.
Moment of Inertia
The molder will not have to be concerned
with changing robot payload handling
capability as it’s reach is extended or it’s
speed is increased.
T=(mr^2)*A
Some non-linear robots often require
considerations for Inertia / Moment-load
as reach is extended or speed (and
acceleration) is increased.
linear motion is not this
complicated
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
Though linear robots can handle the majority of molders needs there are many
applications that 6 axis articulated robots are specifically suited for:
•
•
•
•
•
Edge Routering / Material Removal
Painting / Dispensing
Welding / Laser
Complex assembly
Palletizing
Note also: The 6 axis and Scara type robot can make a great work cell
companion to the Linear robot for special secondary applications.
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
Space Savings
Linear robots, being platen mounted
and not floor mounted, do not
occupy the work envelope that
they need to do value added
operations…thus they require less
floor space and allow the molder
free access to the side of the mold.
Also linear robots have a “Square”
work envelope which nicely
matches the geometry of a molding
machine and the space between
molding machines i.e. typical floor
plans of molding shops.
Linear robots fit “tightly” in molders production
areas.
“Square Foot-print and Square Work-Envelope
Space” fits well in molding shops
Not a lot of extra room
between presses
.
.
D
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
Un-encumbered space for easy mold access
Space Savings…and mobility
Ance
Linear robot systems are mobile. A
great advantage versus floor
mounted robots because only the
conveyor or secondary equipment
“sits” beside the press.
Molders can Simply “Roll” the work cell
away for unrestricted mold access
and maintenance.
3-5 axis Linear robots fit “tightly” in
molders production areas.
Roll-Away work cell
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
Space Savings… is a premium
Large floor space
needed
Typical 6 axis robot
controller
These days most linear robots do
not have a large floor mounted
controller wasting space.
They have robot mounted
controllers and press mounted
pendants…this saves space: 2-4
cubic yards per molding
machine.
3-5 axis Linear robots fit “tightly” in
molders production areas.
Linear robot
controller…
beam mounted
Pic of robot mounted
controller here
Space saving beam
mounted controller
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
Simple is Good
Simplicity…to teach
The “easiest” distance between
2 points is not a compoundknuckled multi-axis motion
but rather 1 or 2 axis
“straight” line.
Molders embrace Linear robots
super-simple graphic pointto-point teaching.
Graphic showing a simple take out
sequence in line form
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
From crate to production in 1 or 2 days
Simplicity…to implement
Simple and Easy Installation and
quick on-site operation training.
From crate to production in 1 or 2
days is common; no other robot
for molding can do this. This is the
benefit of a Linear Servo robot
type that is designed specifically
for molding.
Day 1
Day 2
.
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
Simplicity…in learning curve
Simple and Easy to Teach and
Program…this is a benefit of
inherently easy-to-understand linear
control combined with powerful
graphics.
Linear servo robots also have plenty of
control “horsepower” for the most
demanding of applications with it’s
CNC step-by-step programming.
Simple when the molder needs it,
powerful when the molder needs it:
the best of both worlds.
Graphics
Stepbystep
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
Simplicity…in Graphics
Linear robots typically have
the excellent graphical
based controllers.
From operators to technicians
to engineers…more of the
plant personnel are
empowered to keep the
robot running, optimized
and re-implemented
…thanks to the ease and
power of linear graphical
interfaces.
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
*
$ Cost Effectiveness
They typically are lower priced
than other Non-linear robots
and do not have a long
learning curve or costly
training requirements.
Linear Pricing VS Articulated Pricing
160000
*
140000
120000
Multi-Articulated axis
100000
Base P ricing
Price: Linear Servo Robots are at
the greatest value in their
history. They are faster, easier
to control, super capable and
very flexible at pricing that
barely purchased a low cost
pneumatic robot not long ago.
*
80000
60000
Linear
40000
Linear
20000
0
50
100
250
500
700
Tonnage
1000
1500
2000
3000
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
Don’t call them “Pickers”
Linear servo robots are not just basic
“Pick-n-Place” robots. They now have great…
Flexibility
Speed
Capability
Space Savings
Simplicity
Cost Effectiveness
Performance meets Cost Savings;
the very thing competitive molders need.
Linear Servo Robot Benefits
Resources
Article (pricing reference for 6 axis robots see slide #24): State of the Tech: High-tech
articulated robots for the masses; Oct 2006; by Rob Neilley; Injection Molding Magazine;
ABB data
Content: Slides, pictures, graphs, animation, text: Wittmann Inc.; Author Joe Varone; 5-08