RFQ: Molder in search of flexible automation 
solutions

Our in-house injection molder is in need of some assistance in introducing the latest productivity-enhancing shop floor automation technology.

Dear automation solutions vendor:

Idaho Molding & Mold Corp. (IMM) is a medium-scale injection molding shop operating 45 presses ranging in tonnage from 55-1100 tons. We mold a variety of products including writing instruments, housewares, furniture, and even some electrical and electronic components requiring insert molding. While we do have a certain level of automation on some of our presses, be it simple sprue pickers or Cartesian robots in the case of sensitive parts, we are increasingly facing competition not only from offshore but also domestically due to our relatively remote location. As such, we are actively considering investing in automation cells for subassembly and packaging.

Don’t worry! We don’t plan to lay anyone off. We see our venture into higher levels of automation as a means of improving quality and expanding our business. So what can you offer me in terms of solutions, be they demolding, stacking, and boxing of housewares or handling of complex insert-molded electronic components that might require postmold machining, QC checks, and packing?

Yours truly,
Will Mulder, CEO
Idaho Molding & Mold Corp.

Suppliers respond
Arburg Inc. (Newington, CT)
Arburg would be delighted to support you in automating your production processes. We supply a wide range of hydraulic, hybrid, and electric injection molding machines from 14-550 US tons. We also offer a variety of robotic systems, which are developed and produced in-house and can be fully integrated in our central Selogica control system. Our project department provides expert advice and designs complex systems, including peripherals, specifically to your requirements on a modular basis. Responsibility for each turnkey solution, in which upstream and downstream steps can be integrated, rests completely with us—from consulting and planning through to implementation and commissioning.

As the products you manufacture include household articles that require postprocessing and quality control, we recommend automation using a flexible six-axis robotic system, which enables significant cycle time reductions. One example of such a solution is a production cell that produces thermoset insulating rails for domestic irons. The robotic system removes the parts and transfers them to the subsequent stations. Thanks to its complex 3D movements, deburring can be performed rapidly and reliably. The device then transports the finished parts for optical quality monitoring and final functional checking before stacking them in a space-saving manner.

Because Arburg has implemented the intuitive graphical user interface of the Selogica control system in the robotic system, your installation technicians can independently program and flexibly modify the movement sequences as necessary, without prior specialized knowledge.

For many applications, the linear Multilift robotic system is an interesting alternative. For one customer, for example, we integrated a Multilift V equipped with a complex gripper into a production cell. This removes and positions the individual parts of a folding crate and assembles it simultaneously with the injection molding process. This fully automatic solution achieves huge time savings.

We have also implemented innovative concepts for the production of electronic components. One existing project is a highly automated production cell that produces the plastic parts of a sensor for the automotive industry. This product must meet extremely stringent quality requirements. The automation solution includes separation of the contacts to be encapsulated, their introduction into the mold, automatic removal of the finished molded parts, and transfer to a downstream camera inspection station. The OK parts are set down in blister packs on a palletizing system. The system can operate autonomously for 8-10 hours and is controlled centrally via the Selogica machine control system.

The example of an LED light strip illustrates how complex functions can be integrated into a single production cycle thanks to intelligent mold and process design. The housing and lenses are produced using the three-component injection molding process, while the electronic components are simultaneously encapsulated with a conductive plastic and connected. Assembly of the LEDs and lenses takes place within the mold.

I hope that the above examples have shown you that we are a competent partner to make your production processes more cost-effective and future-proof.

Engel (Schwertberg, Austria)
The trend to a higher level of automation in injection molding continues to spread. This is driven not only by increasing cost pressure and global competition, but also by increasingly stricter quality requirements and the need for comprehensive documentation of the overall process.

In our quotation, we reference an intelligent automation solution at Zehdenick Innovative Metall- und Kunststofftechnik GmbH, which manufactures printed circuit boards for the automotive industry. This is a first-class reference for Idaho Molding & Mold, because both companies are about the same size and seek to achieve similar objectives with their investments.

The highly integrated production cell was supplied by Engel as a turnkey system. It comprises two Engel insert injection molding machines with vertical configurations, a multiple-axis industrial robot, an Engel pick-and-place robot, processing stations for the metal components, quality assurance equipment, and packaging and pellet handling systems.

The process starts by feeding in the punched sheets (right in the picture above). The contact rails to be overmolded are prepared on a punching and bending machine, and fed in to an Engel insert 200V/60-type molding machine. Following the first injection process, the premolded parts are stamped clear of the contact rails. The Engel pick-and-place robot takes the parts off the mold and hands them over to the six-axis robot while maintaining the right orientation for the second injection molding process. This robot, a Kuka KR-16, insert-places the parts into a 2+2-cavity mold on an Engel insert 330V/90-TR injection machine.

After injection molding, the multiple-axis robot takes off the molded parts and feeds them to the quality control station. They then pass through electrical functional testing and a visual check of the parts by means of a camera. The test results are forwarded to central data management. The good parts are deposited directly on plastic trays by the robot for packing, and the robot also sorts the parts into left and right in this step.

The plant was supplied with safety equipment, a safety concept, and CE certification for the complete plant. In this project, Engel was not only responsible for the plastics technology, but also for integrating the metalworking systems. Project partners in this area were Farger & Joosten (Hohentengen, Germany) for the presses and Schröder & Bauer (Neulingen-Bauschlot, Germany) for the stamping bending tools. Engel thus offers its customers single-source process know-how in hybrid technologies, thus ensuring maximum efficiency and process stability—from the planning phase through to operation of the plant.

Where ZIMK formerly insert-placed metal components into the injection molding machine in a manual process, the production cell now works a 24-hour, fully automated shift. Automation ensures a constant cycle and thus reproducible quality. Thanks to integrated quality control, there is no danger of NOK parts being delivered to the customer. ZIMK has thus achieved its goal of 100% quality and comprehensive documentation.

Sepro America LLC (Pittsburgh, PA)
You are quite right when you suggest that the benefits of robotic automation are not derived solely from manpower reduction. In fact, your system can pay for itself quickly even if staffing levels remain the same.

Automation will allow you to gain better control of your process, eliminating human-related inconsistencies, not only potentially shortening your current cycle times, but, more importantly, ensuring consistent cycle times, improving part quality, and preventing part damage that could occur during part ejection, secondary handling, assembly, and packing. You can even integrate machine vision and other QC controls into the automation system.

You say you produce a wide variety of parts and components that range from simple to complex. We would be happy to analyze each of those applications in detail, gathering critical information on the molding machines and tooling, cycle time expectations, the size, shape, and weight of the parts, number of secondary functions to be performed, and specific attributes that contribute to the end quality and profitability of those products. With this information we can provide you with the right solution and an attractive return on investment.

As a starting point, let me describe a turnkey system that would be required to automate the handling of your electronic components, including the feeding and loading of inserts, removal of finished molded parts, postmold cavity separation and visual QC inspection, and finally the packing of the molded parts.

Required equipment
• Insert feed module: feeder bowl and insert escapement track
• Three- or five-axis servo Cartesian beam robot
• Robot mounting riser
• End-of-arm tool (EOAT) for the placement of inserts and removal of finished parts
• QC Station with proximity sensors for insert verification
• Packaging station on conveyor
• Equipment safety guarding enclosures to meet all SPI safety and industry requirements

The sequence of operations would be as follows:
1. Inserts are fed from the feeder bowl down two vibratory tracks and will be staged and put in place for pickup by the robot. The pickup of the inserts will be done in two gripping sequences.
2. The Cartesian robot will pick up the insert(s) from the controlled pickup position with the insert EOAT and, once the robot confirms all inserts are present in the tooling, will move to a ready position above the mold area.
3. As the mold opens, the robot arm descends to the part pickup position and uses vacuum to grip the molded parts as they are ejected from the moving half of the mold. Having captured and verified the removal of the molded parts, the vertical arm moves back and positions the insert tooling against the stationary mold face for placement of the inserts. After docking on the mold face, linear slides will be used to position and seat the inserts into the mold.
4. After the inserts are placed into the mold the robot arm traverses out of mold area and passes the QC inspection station, where proximity sensors detect the presence/absence of inserts in each part. If defects are detected, the robot drops the entire shot into a reject bin for further examination and recycling.
5. Once all inserts have been verified, the robot traverses to the packaging station. The EOAT flips 90° so that it can place the parts in a packing box. The robot is programmed to create six layers of 24 parts (total parts per box = 144), placing a cardboard packing sheet between each completed layer.   
6. Finally, the robot returns to the insert pick up location and begins the next cycle.

Total cycle time: 33 seconds.

This system uses readily available components and can be delivered and installed in your plant within 10 weeks after the receipt of the purchase order and upon receipt of all tool, part, and insert drawings, including part and insert samples. A work scope acceptance procedure will be presented for approval along with the design review drawings. A runoff of the workcell will take place at our location to ensure all requirements are met prior to shipment. Once received at time of startup, we will ensure that all of your employees are properly trained to run this automation cell.

Thank you for this opportunity to serve Idaho Molding & Mold Corp.

Wittmann Battenfeld Inc. (Torrington, CT)
Thank you for your recent inquiry regarding robots and automation solutions for your company. Please review our five questions below. Your answers will help us learn more about your operations and allow us to provide you with specific solutions.

1. What is the tonnage of the injection machines (IMs) that need automation? You mention that you have press sizes ranging from 55-1100 tons. We can offer unique solutions for each tonnage size of machine.
2. What are the ages of the IMs currently in use? It is important to realize that the new technologies of IMs and robots, along with auxiliaries, can make a huge difference as to how you are able to process and ultimately compete.
3. Do the current IMs have robot interfaces? Is there an overhead clearance issue? What type of power is available (230V AC or 480V AC)? Do you have additional air supply capacity? When looking at adding robots and IMs, along with auxiliaries, knowing what is needed can be a major concern and in some cases can cause delays to projects and extra cost. Your application and plant questionnaire is an important tool in conjunction with your local representative’s knowledge to reduce the surprises that can happen and keep the project on time and on budget.
4. What cycle times are you running? As we determine the best solution, knowing current and desired potential cycle time is critical. Wittmann Battenfeld offers three choices in robot speeds to customize the best options for your application.
5. Do you have in-house maintenance or engineering for automation and robotics? Wittmann Battenfeld injection molding machines and integrated robots are available with 24/7 Web support. Technicians can see the machine and log into the controls for programming and troubleshooting help.

Some additional considerations:
a. Central material handling can improve process flow and floor space, especially if you use gaylords currently by the press. Also by using a centralized system, drying and blending can be located in one area to save additional floor space. Also using our M7.2 control platform coded coupler stations and system control can eliminate mistakes of incorrect materials going to the wrong presses and accounting for material with the process monitor control functions.

b. Water Temperature controllers (TCU’s) can improve cycle times by quickly conveying heat away or adding heat to the mold. With features such as Leak Stop with the flip of a switch you can eliminate small core leaks to complete runs without having to pull the mold for repair. If using hot oil for molds consider water units that heat to 350 degrees F. They are safer and more
efficient than oil, with any leaks turning to steam instantly.

c. Granulation of products can reduce the dependence on virgin material and provide a way to recycle runners or parts back into the product. Screenless models and water jacket chambers improve the quality and size of the regrind to make it easier to process. Available hopper magnets prevent accidental contamination of metal objects from damaging the blades and saves costly
repairs.

We would like the opportunity to visit your plant, meet with you, and review your operations. This will help us identify these and perhaps other potential time- and cost-saving items.

Yushin America Inc. (Cranston, RI)
Thank you for contacting us regarding your higher-level automation project. Yushin America offers a wide range of solutions for demolding and packaging needs. I agree with you that in order for injection molding companies to stay competitive in this highly competitive global market, they must reduce labor costs while maintaining a high level of quality and maximizing productivity. This can be accomplished by implementing an automated workcell beside the molding machine that will reduce manual labor and improve the overall manufacturing process.

The Yushin RC-II Series full servo traverse robot is a great starting point as the RC Series is designed to serve a wide range of injection molding machines sized from 15-5000 tons, and can be configured as a single- or double-arm robot. Molded parts can be picked with one arm and inserts placed into the opposite side of the mold with the other.

The rigid robust construction of the RC-II robot provides a huge increase in part extraction speed and allows for vibration-free, precise product picking and placing. The RC Series robot is a general-purpose robot that performs high-speed takeout, elevating productivity levels to new heights. High-precision repeatable positioning accuracy is essential for such functions as loading inserts into a mold or placing molded parts into tight-tolerance pockets of thermoformed trays for final shipping or interdepartmental transport.

The robot can be equipped with an NC servo wrist that can flip or rotate end-of-arm tooling to very precise user-programmed angles. The RC Series robot equipped with the NC servo wrist can have up to seven numerically controlled axes, giving range and flexibility to handle any of your downstream packaging, assembly, or quality needs.

The RC Series robot comes equipped with the E-touch II control featuring a large touch-screen monitor and an easy operation directional touch pad for quick mold setup or teaching and online programming. The control features an intuitive 3D motion chart interface that includes positions, speeds, and timers on one easy-to-use screen. The E-touch II control is also equipped with voice guidance technology and a built-in casing routine for tray or carton loading.

Yushin also offers an end-of-arm-tooling (EOAT) quick-change unit that can be configured to be manual or automatic. The quick change can greatly reduce setup times by allowing the instant attachment/detachment of the EOAT wiring and pneumatic connections with the touch of a button. The automatic quick-change option allows the robot to change production tools automatically during the automatic molding cycle.

Thank you for considering Yushin for your automation needs.

—Stephen Moore