Plastics Industry - New 3rd Generation robots are leading the way
6 axis robots offer many advantages over their linear gantry predecessors including: longer service lives, lower maintenance requirements, faster, near 100% availability, greater stiffness of the arm, smaller compact size, clean room friendly, lower mold costs and higher quality output. However, to really maximize these advantages you must think outside the square.
Major Robotic manufacturers are forecasting that the plastic industry represents one of the major growth areas in the short to medium term, and beyond. Considering how much of all consumable products consists of plastic, from mobile phones through to car interiors, it is no wonder.
Maximising Your Investment
The reason all companies turn to automation is to be able to remain competitive. However, it is key when investing in automated robotic solutions that consideration is given to maximizing the productivity of the robot beyond the specific application. Benefits such as optimised work processes and shortened cycle times can be capitalised even further with the selection of the right robot. If non-productive time that previously went unused can be used efficiently by implementing a robot that offers more flexibility, the return on investment can be increased considerably.
Therefore, where previously the linear gantry robot roll was specific to the unloading, now a robot can carry out the loading and unloading, but also the
additional processing steps right up to the final set-down of the part. With a simple change of tools, a single robot type can be used to implement a number of different sub-processes. An example of this can be seen in the case study, where the removal of
bumpers is followed up with the high-precision finishing in the visible area where no additional periphery is required.
Utilisation
With the correct planning a single robot can be setup and programmed to do a range of activities including:
Demoulding
Due to its tremendous freedom of movement, the shelf-mounted robot can even remove parts from undercut moulds more quickly either with force or delicately, as required by the application.
Setting Down and Locating
The robot holds the part in a device on its writs where sprue can be removed or stamping operations can be carried out. The corresponding automation process can be expanded or modified step by step.
Removing Sprue and Webs
The robot removes Sprue and Webs along precise contours, even on the visible side of the work piece. From the prototype to the production part, re-designs and component modifications can be made in a minimum of time by means of simple program changes.
Inspection and Final Set-Down
Machining is followed by a quality inspection and application of a barcode. Then the robot sets the component down on a cooling conveyor or - depending on the palletizing method - in a transport frame.
Other Benefits
Another benefit that new robotic technology can deliver is machine synchronization. The position sensing system of the machine is continuously coordinated with the robot position, thus guaranteeing optimal cycles, reducing wear on the robot arm and preventing costly collisions between the mould and the end-effector.
Advantages and Benefits
An example of this is the 3rd generation robots from KUKA that deliver a range of advantages that can be taken benefit the rest of your operations.
. Reduced weight of the robot arm
. Reduced floor space requirement
. Less space required overhead
. Larger envelope depth to the front and below for de-moulding and setting down parts.
. Robot knee (intersection of axes 1 and 2) moved forward and down to move around obstacles
. Point of application just above the fixed tool clamping surface
. Optimal synchronization with the machine due to improved software packages
The Benefits
With careful planning major savings be realised.
. Optimized cycle times through the use of non-productive time for finishing
. Complex removal from moulds with 3D undercutting
. 3D unloading synchronized with the machine
. Reduced rejects
. Higher availability
. Up to 30% greater output
. Reduced personnel requirements
. Up to 40% time savings for unloading
. A second handling unit for delicate operations is no longer needed
. Ideal combination for high carrying capacities and precise unloading
Machinery Automation & Robotics
1/101 Derby Street
Silverwater NSW 2128
Phone: (61) 2 9748 7001
http://www.machineryautomation.com.au