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Automated ball bearing assembly

Automatisierte Kugellagermontage

Spritzguss

Injection molding

注塑成型

injection-molding

In this video, we present an advanced solution for the automated assembly of ball bearings in production. The setup of the gantry system and the integration of the Epson Scara are shown, as well as the operation of the rotary conveyor and the Variobotic shaker cameras for precise detection and positioning of the ball bearing components. The Schunk and Schmalz grippers are demonstrated in action, handling the ball bearings safely and efficiently. The step feeder supports the process with its precise conveying technique, ensuring that the entire system operates smoothly and efficiently thanks to reliable power and data transmission. The benefits of this solution include increased production speed, reduced scrap, and improved workplace safety. Additionally, a low footprint is ensured, facilitating integration into various production environments.

Produktion

Manufacturing

Production

製造業

Fabricação

Productie

Produkcja

การผลิต

制造业

Üretim

제조

Produzione

manufacturing

Automated insertion into injection molding machine

Automatisiertes Einlegen in Spritzgussmaschine

In this video, we demonstrate the use of an automated system for inserting components into an injection molding machine. This innovative solution optimizes the production process and significantly increases efficiency.

The operation of the insertion process is shown step by step, demonstrating the precise positioning and handling of the components. The seamless integration of the insertion system into the existing injection molding machine will then be demonstrated, including the communication interfaces and control logic.

The benefits of this solution include increasing production speed and accuracy, reducing scrap and material waste, and improving worker safety by minimizing manual intervention.

An important aspect here is maintaining a low footprint.

Automated material handling with igus room gantry

Automatisiertes Materialhandling mit igus Raumportal

Pick & Place

Pick-and-Place

Al ve yerleştir

拾取&放置

픽 앤 플레이스

ピック&プレース

Pick &amp: Place

取放 (揀選 & 放置)

Pick and place

หยิบและวาง

pick-n-place

In automation technology, 3-finger grippers are of great importance due to their adaptability and precision when handling a wide variety of objects. A recent customer test examined the performance of such a gripper when picking up components from a fixture and assembling them.

The 3-finger gripper demonstrated high precision in picking and reliable assembly of the components. The speed of the process and the low error rate confirmed the suitability of the gripper for production use.

The test underlined the advantages of the 3-finger gripper in terms of flexibility and reliability, making it a valuable component for automated assembly processes. The results support the integration of the gripper into existing and new production lines to further increase efficiency.

Automated parts handling with igus room gantry

Automatisiertes Teilehandling mit igus Raumportal

Pick and place applications are a central component of modern production processes, especially in automation technology. They make it possible to pick up objects precisely and place or assemble them at a defined location. This process is particularly relevant for the assembly of small, lightweight components such as plastic lids.

The test is intended to evaluate the efficiency and precision of the pick and place application when picking up and assembling plastic lids. Particular attention will be paid to the speed of the process, the error rate and integration into existing production lines.

The application consists of a pick and place robot equipped with a gripper system specially designed for plastic lids. The robotic arm is able to pick up the lids at high speed and place them on the corresponding containers by pushing the lid into the opening.

The pick and place application for picking up and fitting plastic lids shows that significant improvements in production efficiency can be achieved through the use of robotics and automation technology. The results of the customer test confirm the potential of this technology to optimize modern production processes and increase competitiveness.

機械人&射出成型機

Robolink & Injection Molding Machine

Robolink & Máquina de moldagem por injeção

Robolink和注塑机

Robolink & spuitgietmachine

Automatisiertes Teilehandling für effiziente Spritzgießautomaten

Robolink e macchina per lo stampaggio ad iniezione

Bestückung

Obsługa maszyn

Mantenimiento de máquinas

Machine tending

機械加工

Machine bedienen

机器操作

기계 관리

機器維護

Équipement

machine-tending

Plastics industry: Automated parts handling for efficient injection molding machines

Whereas employees used to have to place ice scrapers in an injection molding machine hundreds of times per shift, this monotonous task is now performed by a low-cost robot. It is so cost-effective and easy to operate that the investment in automated parts handling pays for itself after just four months.

Monday morning, start of shift at a manufacturer of ice scrapers. An employee places twenty blanks in a magazine and starts the BOY 35 EVV, an injection molding machine that overmolds the scrapers with a lip made of thermoplastic elastomer (TPE). What follows is an example of part handling automation in the plastics industry. robolink, a four-axis robotic arm from Cologne-based plastics specialist igus, grips a blank with a vacuum end effector. The arm then moves to the overmolding machine. The highlight: there are also suction cups on the back of the end effector. This allows the arm to pick up a finished overmolded ice scraper, then turn 180 degrees and place the next blank - with a repeat accuracy of 0.8 millimeters. Removal and loading thus take place in a single motion cycle. And that saves time. The robot arm then places the finished ice scraper on a conveyor belt.

The solution for automated parts handling on an injection molding machine was on display for the first time at Fakuma 2018, the International Trade Fair for Plastics Processing in Friedrichshafen. "The topic of automation is growing strongly in the plastics industry," says Bernd Fischer, division manager for application technology and service at Dr. BOY, a company based in Rhineland-Palatinate, Germany, specializing in the development of injection molding machines since 1968. "Unlike a few years ago, more and more machines are leaving our factory automated today." Before this automation phase, workers had to insert blanks into the machine by hand. Hundreds of times per shift. A monotonous job that is inefficient, tiring and error-prone.

Automated parts handling: payback after approx. four months

Packaging, technical parts, semi-finished products and consumer goods: The plastics processing industry is one of the most important sectors of the German economy. According to the German Plastics Processing Industry Association (Gesamtverband Kunststoffverarbeitende Industrie - GKV), more than 330,000 employees, mainly from small and medium-sized enterprises, generate annual sales of over 65 billion euros. However, this balance sheet is no reason to rest on one's laurels. After all, the sector is going through a transformation phase - just like most other industries. Cost pressure is increasing. And topics such as automation and Industry 4.0 are becoming a competitive factor.

"However, many companies shy away from the topic of automation because they fear investment costs of several hundred thousand euros," says Norman Franke, Head of Automation Injection Molding at igus. "Yet today, thanks to low-cost robotics, it is easily possible to automate monotonous and dangerous processes at low cost and low risk. For example, the robolink robot arm with 5-DOF costs from 3,845 euros - a fraction of the price of conventional industrial robots." The reason for the low cost: Many components of the robotic arm, such as bearings and gears, are not made of metal but of high-performance plastic.

"The investment can pay for itself after just four months," Fischer emphasizes. This is because employees now only have to spend ten percent of their working time on parts handling - namely refilling ice scraper blanks into a magazine from which the robot arm serves itself.

Low-cost robotics is not only comparatively inexpensive to purchase, but also to operate. That starts with operation. "Many companies fear that they will have to spend a lot of money on IT experts to program the robotic arm," says Fischer. "But in fact, after a training period of just a few hours, it's possible even for IT laypeople to define motion sequences." This is made possible by software from Commonplace Robotics, whose origins go back to adult education.

At its heart: a 3D simulation of the robot arm. A Digital Twin of the real robot. Instead of programming, employees define the start and target positions of the arm with mouse clicks. The software calculates the motion paths automatically. It is also possible to insert your own 3D objects. The matching robot controller, integrated in a control cabinet as a DIN rail version, takes care of controlling the stepper motors - and communicates with the controller of the connective injection molding machine via EUROMAP interface. "We have designed the operation of the system so intuitively that the need for IT specialists is reduced to a minimum," emphasizes Fischer. "This saves costs and counteracts the problem of a shortage of skilled workers, which also affects the plastics processing industry."

Since the bearings of the robot arm are made of high-performance plastic and not metal, dry running is possible without lubricants. The lightweight plastic components also reduce energy consumption - another savings factor in times of rising energy costs. Last but not least, the automation does not even require additional space. "The automation of parts handling takes place within the 1.67 square meter footprint of the compact insert molding machine. The company does not have to provide additional space. The low-cost robot, the parts magazine and the conveyor belt are positioned on the free machine table of the injection molding machine to save space."

Low-cost automation of injection molding machines faces a hungry market, Fischer is convinced. He says the solution is particularly suitable for machines with longer cycles. "For cycle times of more than 30 seconds, it makes economic sense for companies to automate part handling with low-cost robotics." For faster machines, on the other hand, robolink is too slow, he said. The robotic arm moves at a maximum speed of 0.25 meters per second and manages seven picks per minute.

Driving automation forward: Online platform RBTX bundles expertise of several manufacturers

If companies like the automated parts handling, they have the option of expanding the automation. This is where RBTX comes in, an online marketplace where manufacturers of low-cost robotics pool their products and expertise. Companies put together automation solutions with the help of a configurator. Robots from igus, for example, provide the basic electro-mechanical framework - including Cartesian robots, jointed-arm robots and delta robots. They can be combined with components from various manufacturers, including vision systems, grippers, interactive software, power electronics, motors, sensors and control systems. Nasty surprises regarding compatibility are ruled out. "To ensure that even small medium-sized companies can make the low-risk leap into the automation age, engineers have already combined and tested all the components," says Franke. "This ensures smooth interaction. Companies can conveniently put together solutions and get started right away."

igus robolink - pick & place in a three-shift operation

Pick & Place-Roboter im 3-Schichtbetrieb

易格斯robolink - 三班倒执行拾放任务

igus robolink - 3교대 작업에 사용되는 픽 앤 플레이스

igus robolink - pick & place in een drieploegendienst

igus 機器手臂robolink - 在三班操作中拾放零件

Handhabung

Manuseio de materiais

Malzeme taşıma

Material handling

Przeładunek materiałów

Manipulación de materiales

倉儲物流

物料搬运

Materiaal handling

ระบบจัดการสินค้า

물류 산업

Movimentazione dei materiali

マテリアルハンドリング

Manipulation

material-handling

Medium-sized industrial companies are confronted with high automation pressure. Robotics does not have to be expensive. A pick-and-place robot that paid for itself in record time shows how to get started cost-effectively and at low risk.

Automation with low-cost robotics helps industrial companies increase productivity and achieve consistent product quality. This is demonstrated by an injection molding system for bearing caps at the Cologne-based company igus. Whereas employees used to have to insert the plastic spherical caps into the machine by hand, this task is now performed by robolink - a robotic arm with four degrees of freedom and a reach of 510 millimeters. The arm picks up the calottes with a gripper and places them in the machine, with a repeatability of 0.5 millimeters and at a speed of 0.25 m/s. After overmolding with fiberglass-reinforced plastic and automatic ejection of the component, the process starts again. 250,000 times per year and in three-shift operation.

"With manual monotonous work in industry, there is a risk of employees becoming tired and product quality suffering due to operating errors. With the help of the introduction of low-cost robotics, we have succeeded in relieving employees and further increasing product quality," says Norman Franke, Head of Automation Injection Molding at igus. "In addition, the productivity of the injection molding machine has increased because the system continues to run even when employees are on break."

Low Cost Robotic: Investment pays off after approx. four months

The advance of robots does not have to be expensive. Quite the opposite. In this case, it is so inexpensive that even small and medium-sized enterprises (SMEs) can experiment with automation and jump on the Industry 4.0 bandwagon. For example, a robolink costs from 2,766 euros - hardly more than a powerful home computer and many times less than comparable robot arms, which cost tens of thousands of euros. The reason for the price is that many components of the robotic arm, such as the gearbox, are not made of metal but of triboplastics. The controller from Commonplace Robotics costs 1,897 euros, and a parallel gripper from Schunk costs around 100 euros. "The bottom line is that investing in such a low-cost robotic solution is low-risk," Franke says. "We achieved the return on investment in about four months."

For industrial companies, the pressure to automate is becoming stronger

According to the online portal Statista, manufacturers sold 381,000 industrial robots worldwide in 2017 - for handling, assembling and processing workpieces. By 2021, this figure is expected to reach 630,000. The benefits of advancing automation are enormous: With their help, industry could generate additional value added of 1.25 trillion euros in 2025, predicts the Federation of German Industries (BDI). Not only because companies will become more productive, but also more flexible and individual. The key words are Industry 4.0 and batch size one.

The problem is that while sectors such as the automotive and aerospace industries are increasingly benefiting from automation and networking, many SMEs are reluctant to do so. Not only for cost reasons. It's also because of the complex interplay of components from different manufacturers - including mechatronics, control systems and software. In addition, acceptance among employees is often low because they fear job losses.

Leading robotics manufacturers united in one kit

Removing these obstacles is one of the goals of RBTX - a marketplace for low-cost robotics that unites manufacturers of robotics components in a construction kit. The electro-mechanical basic framework is formed by robots from igus, among others - including jointed-arm robots, delta robots and Cartesian robots. This basis can be expanded with individual components from various manufacturers, such as grippers, cameras, interactive software, power electronics, motors, sensors and controllers. Customers can put together a robot solution with just a few clicks. Compatibility is guaranteed, explains Franke: "Companies enjoy investment security because we have assembled all the components in various combinations and tested them in detail."

The low-cost robotic solution used in the injection molding machine from igus enjoys acceptance among employees. Because it was clear from the start: The transformation optimizes the production process, but does not lead to job losses. Because employees who previously had to struggle with monotonous tasks took part in a training course. They learned how to operate the robotic arm and even teach it new movement sequences. A three-day training course was all it took. "The control system from Commonplace Robotics was originally educational software and is child's play to operate - without any programming knowledge," Franke emphasizes. "The employees are enthusiastic about the technology because it not only simplifies the work, but also makes it fun."

Low maintenance and quick repairs: robolink ensures cost-effective operation

The automation of the injection molding system was not only cost-effective to purchase, but is also cost-effective to operate. This is because the robolink robot arm is made of tribopolymers, which enable dry running without lubricants. Accordingly, there are no costs for materials and maintenance. And repairs are also comparatively simple. To help technicians help themselves, repair instructions are documented on the Internet. In addition, RBTX offers spare parts supply within 24 hours. Franke: "It has actually never been easier to get into automation."

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