FlexibilitySpeed
CapabilitySpace Savings
SimplicityCost Effectiveness
Injection Molding and Linear Servo Robots
X Y Z A B CX Y Z A B C
The Benefits of Linear Servo Robots…
All Robots share the same justification premise: To reduce costs for the manufacturer. Cost reduction examples:
Direct labor savingsQuality improvementScrap reductionCycle time reductionsValue added operationSafety 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
The flexibility of the linear robot traverse beam for re-orientationallows molders to adapt from application to application quickly and easily on any side of the molding machine.
Flexibility…mechanical
From Operator side and Rear side discharge to T-Beam and Longitudinal-
Mount
Mechanical Re-Orientation Flexibility
RearRear
TT--BeamBeam LongitudinalLongitudinalOperatorOperator
Injection Molding and Linear Servo Robots
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.
Flexibility…and safety
Mechanical Re-Orientation Flexibility
Operator side parts handling
Picking parts from the mold and placing to the operator side is one of several standard linear
configurations
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
.
The linear servo robot can handle two sides of the molding press within each molding cycle by using a standard T-Beamconfiguration 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.
Flexibility…
Separate good product from rejects
Great use of space and quality control
TT--BeamBeam
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
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.
Flexibility…reach
E
Clamp-end parts release
Create a value stream flowCreate a value stream flow
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
Beware of “Over-Buying” the idea of Flexibility
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.
Flexibility…
.
Only 3 axis are needed for a 3-D work envelope
Work Envelope
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
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 un-knuckled 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
Speed…the Top Entry
> Speed = > ROI> Speed = > ROI
Top Entry High Speed Linear Robot
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
Linear side entry robots are built with one thing in mind… Speed. ..for fast molding cycles.
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.
The benefit of speed and simplicity of 2-3 linear axis.
Speed…the Side Entry.
>> Speed = Speed = >> ROIROI
Show Movie Clip of a W7X5HS side entry
Scara-robot here
.2s take.2s take -- out tim
esout tim
es ……
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Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
IML: In Mold LabelingIML: In Mold Labeling
Now built for more Capability and Payload handling, linear side entry robots handle IML mold applications very effectively.
Speed…meets capability
High Speed IML: Stack mold label loading and part removal
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
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
Capability…
Linear motion combined with articulated motion
Articulated A and B servo
wrist axis
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
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.
Secondary operationsDegatingSortingInsert loadingTote / Box loadingPalletizingIntegration for labeling, serial coding, bagging etc.
Capability…secondary operations
Systems Integration
Systems Integration …
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…....
H
Metal Insert Loading
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
Linear servo robots have color high resolution control pendants that do much more than just axis 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…
Capability…in control
AController Capability Controller Capability …
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Multi-Operator interfaces
Built-In Operation Manuals
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
Linear control capability and multi axis capability handles Pre-mold and Over-mold applications well.
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…special applications
Show pic one robot serving 2 machines
Capability above and beyondCapability above and beyond …
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…....
Show pic of 743SO robotGreat for Structural Foam
Demolding
Pre-mold / Overmolding
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
Also…Linear robots are well designed to handle Stack molds and 3 Plate molds.
Stack mold de-molding is not so simple with other types of robots.
Capability…3 plate molds
Show pic 744D
Stack molds and 3 plate m
oldsStack m
olds and 3 plate molds ……
Injection Molding and Linear Servo Robots
Linear Servo Robot BenefitsTwo Main Arms for Demolding
Three Plate Molds
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.
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.
Some non-linear robots often require considerations for Inertia / Moment-load as reach is extended or speed (and acceleration) is increased.
Capability…and constantsMoment of Inertia
T=(mr^2)*A
Linear robots: the payload handling is the payload handling…simple.
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
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.
Space Savings
.
.D
“Square Foot-print and Square Work-Envelope Space” fits well in molding shops
Not a lot of extra room between presses
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
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.
Space Savings…and mobility AnceUn-encumbered space for easy mold access
Roll-Away work cell
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
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.
Space Savings… is a premium
Space saving beam mounted controller
Large floor space needed
Linear robot controller…
beam mounted
Typical 6 axis robot controller
PicPic of robot mounted of robot mounted controller herecontroller here
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
The “easiest” distance between 2 points is not a compound-knuckled multi-axis motion but rather 1 or 2 axis “straight” line.
Molders embrace Linear robots super-simple graphic point-to-point teaching.
Simplicity…to teach Graphic showing a simple take out sequence in line form
Simple is Good
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
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.
Simplicity…to implement
.
From crate to production in 1 or 2 days
Day 1
Day 2
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
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.
Simplicity…in learning curveGraphicsGraphics
StepStep--byby--stepstep
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
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.
Simplicity…in Graphics
Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
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.
They typically are lower priced than other Non-linear robots and do not have a long learning curve or costly training requirements.
Cost Effectiveness$$
Linear
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Injection Molding and Linear Servo Robots
Linear Servo Robot Benefits
Linear Pricing VS Articulated Pricing
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Linear
Don’t call them “Pickers”
Linear servo robots are not just basic “Pick-n-Place” robots. They now have great…
FlexibilitySpeed
CapabilitySpace Savings
SimplicityCost Effectiveness
Performance meets Cost Savings;the very thing competitive molders need.
Injection Molding and Linear Servo Robots
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
Linear Servo Robot Benefits