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TOPSTAR Cartesian Injection Robot Installation & Commissioning Guide

2026/10/14 By le zhan

TOPSTAR Cartesian Injection Robot Installation & Commissioning Guide

The installation Cartesian injection robot consists of four stages: equipment isolation and work area safety protection; preparation of the installation site; Cartesian injection robot installation and connection; and verification of synchronized operation with the injection molding machine. A correct and reliable installation requires ensuring that the mounting brackets are accurately positioned, that electrical and signal connections are properly matched, and that motion programs are verified before production begins.

In our installation video, we demonstrate the entire installation process using the T5-80s robot and the TS170 injection molding machine. This installation guide also provides detailed explanations of the installation steps and key inspection points for each stage. Be sure to refer to the installation drawings, wiring diagrams, and operating manual provided with the equipment to verify dimensions, connection details, and all configuration parameters.

What Should Be Checked Before Installing a Cartesian Injection Robot?

Pre-installation preparations begin with a thorough inspection and assessment of the entire production unit. The robot requires sufficient space for movement, an appropriate installation layout, and utilities (such as power and compressed air) that match its configuration. Before hoisting the robot into place, please complete the following two stages.

Ensure Safety in the Robot Installation Area

Before performing mechanical installation or wiring, the injection molding machine and robot must be isolated from hazardous energy sources. Follow the on-site “lockout” procedures to verify isolation and control stored energy that could cause unintended movement. (OSHA (Occupational Safety and Health Administration) guidelines on hazardous energy also list energy isolation and stored energy control as necessary precautions during relevant maintenance operations.)

Installation personnel must wear hard hats, safety shoes, and reflective vests. Personnel must remain clear of the robot’s path of movement, and a restricted installation area must be established. Before moving the robot, prepare for the lifting operation. Check the lifting equipment’s load capacity, inspect the lifting slings, and verify the lifting points specified in the equipment’s technical documentation. Ensure personnel stay clear of suspended equipment and prevent unauthorized activities from taking place within the lifting area.

Before proceeding, verify the following:

  • The equipment’s isolation status has been verified.
  • Restrictions have been implemented in the installation and lifting areas.
  • The lifting equipment and lifting points meet requirements.
  • The robot’s intended path of movement is unobstructed.

These precautions must be strictly observed throughout the entire installation and connection process. Controlled commissioning may only begin after the installation inspection has been completed.

(See video at approximately 0:36)

Prepare Tools and Check Clearance Around the Injection Molding Robot

The installation requires tools such as lifting slings, a multimeter, screwdrivers, wrenches, and sockets. In addition to these tools, you must also have the specified fasteners, installation components, connection fittings, and equipment drawings ready. Before installing the mounting bracket, check the clearance around the injection molding machine. Dry hoppers, overhead cranes, piping systems, and nearby equipment may interfere with the installation or the Cartesian injection robot’s subsequent movements.

Assess the robot’s expected working range (working envelope), including the paths to the mold area and the product placement area. (Note: A clear installation location does not necessarily guarantee sufficient operating clearance throughout the entire part-retrieval cycle!)

Next, check the on-site power supply against the robot’s nameplate and wiring diagrams. Any live-wire measurements must be performed by qualified personnel in accordance with standard procedures; be sure to disconnect the power supply before wiring.

Proceed with subsequent operations only after confirming that installation compatibility, motion clearance, tooling, and utility requirements are all met.
(See approximately 1:45 in the video for details.)

Prepare Tools and Check Clearance Around the Injection Molding Robot

How to Connect, Commission, and Install a Cartesian Injection Robot?

Once the site is ready, complete the mechanical installation first, followed by connecting the power and control lines (utility connections). Next, verify each individual function before testing the coordinated motion sequences. The following two stages cover the installation, connection, and commissioning processes.

Installing the Injection Molding Robot and Connecting Various Lines

First, complete the mechanical installation and alignment, then connect the power supply, machine tool signal cables, compressed air lines, and the teach pendant.

Installation and Alignment of the Injection Molding Robot

Verify the hole layout of the mounting bracket against the approved installation drawings for the injection molding machine to confirm the installation position, fastener specifications, and thread requirements. Note: If any missing or mismatched mounting holes are found, be sure to consult the equipment supplier or the responsible engineer before drilling holes or replacing the mounting bracket!

Use the approved lifting plan to hoist the robot above the mounting bracket. Align the mounting holes, install the specified fasteners, and ensure stable support during positioning. Check the robot’s position and parallelism against the manufacturer’s specified reference points, then tighten the fasteners to the specified torque. Clear away any debris generated during installation and ensure that no tools or loose parts are left around moving components.
(See approximately 3:27 in the video)

Installation and Alignment of the Injection Molding Robot

Electrical, Signal, and Pneumatic Connections

Before commissioning, verify all connections by referring to the equipment wiring diagram:

ConnectionInstallation check
Electrical supplyConfirm the specified voltage, wiring arrangement, and protective grounding
Machine I/OMatch connections to the approved signal list and interface diagram
Compressed airConnect to the designated inlet and set the specified pressure
Operation pendantConnect securely and keep its cable clear of moving components

Our video demonstrates the “Molding Complete” signal labeled “#13.” This definition applies only to the configuration shown in the demonstration; be sure to consult the actual equipment’s documentation before connecting signal wires.
Finally, secure the cables and air hoses, ensuring sufficient slack is provided, and keep them away from pinch points, sharp edges, and high-temperature surfaces.
(See approximately 4:46 in the video)

Electrical, Signal, and Pneumatic Connections

Pre-Production Robot Commissioning

We have listed five commissioning check items: Power-On, Manual Operation, Home Positioning, Signal Testing, and Simulated Operation. Please follow the specified commissioning procedure and perform these steps in sequence.

  1. Power-On and Air Supply Check:
    Confirm that the controller starts up normally and check for any alarm indications. Inspect the pneumatic connections for leaks and verify that the operating pressure meets specifications.
  2. Manual Movement Check:
    With the motion area clear of obstacles, test each axis using the specified commissioning settings. Confirm that the movement directions are correct and ensure sufficient safety clearance between the robot and the injection molding machine, mold, hopper, and surrounding equipment.
  3. Home Position Check:
    Execute the approved home position procedure. Confirm that all axes can establish their reference positions and that no collisions or abnormal movements occur during the process.
  4. I/O (Input/Output) Check:
    Use the monitoring screen on the teach pendant (handheld operator unit) to compare signal statuses with the machine’s actual operating conditions. Before proceeding to the next steps, identify and resolve any issues involving missing, reversed, or inconsistent signals. Complete the necessary emergency stop and safety interlock function verifications in accordance with the equipment’s technical documentation.
  5. Simulation Run:
    Test the coordinated motion sequence under controlled conditions. Verify that the robot enters the mold area only when permitted, completes the part retrieval operation, and returns to a safe position before the injection molding machine performs its next action.

Installation is considered complete when the robot is securely mounted, utilities meet specification requirements, reference positions are set, and the coordinated motion sequence between the injection molding machine and the robot has passed all necessary checks. The successful installation of a Cartesian injection molding robot signifies that all verification tasks for installation, connection, and coordinated operation have been completed prior to formal production.
(See the video at approximately 6:25–6:40)

Pre-Production Robot Commissioning

This concludes the overview of the Cartesian injection molding robot installation; for further details, please watch the full video.（https://www.facebook.com/reel/1381934390245536）

 

 



 

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