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The importance of a 3 axis robot for injection molding in the high-speed packaging industry

2025/05/12 By Topstar

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When facing the injection molding production of high-speed and surging industries such as the high-speed packaging industry, it is necessary to make our injection molding equipment capable of large-order production and efficient intelligence. In addition to the core injection molding machine, a 3 axis robot is also required and integrated with the injection molding machine to complete the injection molding. The high-speed packaging industry’s output per shift usually exceeds tens of thousands of parts. Topstar’s three-axis robot is built on a powerful open control system and a five-in-one servo drive to provide the speed and precision required for continuous production. The uninterrupted workflow is maintained by coordinating precise part removal, handling, and transfer tasks in sync with the injection cycle, significantly reducing cycle time and labor dependence.

Using 3 axis robot to achieve continuous production of injection molding

A significant advantage of 3 axis injection molding robots is that they can achieve continuous production. Clearing jams, changing molds, or adjusting part positions in high-speed packaging may lead to production interruptions and affect the final production delivery. Topstar tightly integrates its 3 axis robot with the injection molding machine’s control system. It can adjust its pick-and-place trajectory based on real-time signals from the two unified communication languages. This synchronization ensures that the three-axis robot can quickly remove the finished part after completing a cycle, place it on the conveyor or secondary operation, and return to its position for the next cycle without human intervention. Achieving a seamless, 24/7 production line that can handle many orders is critical for brands to scale up in response to market demand surges. In addition, built-in diagnostics monitor cycle variations to improve overall equipment efficiency.

injection molding robots Modular design brings flexibility

Unlocking multi-track applications for 3 axis robot

Beyond simple demolding, high-speed packaging and even some other high-speed molding applications require 3 axis robots to achieve multi-track applications to handle different part geometries and processes. Under the self-developed open system, users can write applications tasks such as pulling, undercutting, slips, diagonal lines, and even irregular removal paths. Specialized end-of-arm tools on the 3 axis robot can perform in-line arrangement, precise stacking, batch counting, and statistical sampling for quality control in a single unit. This flexibility enables a single automation workstation to accommodate multiple product lines, thereby reducing capital expenditures and factory footprint, while maintaining high accuracy and adaptability as packaging designs evolve, thereby reducing setup time and achieving seasonal order fluctuations.

Vibration suppression for high-precision molding

High-speed molding inevitably brings vibration problems, affecting part quality and triggering system alarms. The vibration suppression function integrated on the 3 axis robot can actively suppress vibration during rapid acceleration and deceleration. By analyzing the feedback from the high-resolution encoder and the 3 axis inertial measurement unit, the control system of the injection molding manipulator can modify the motion trajectory in real time, smooth the transition, and prevent resonance, thereby avoiding resonance that causes part misalignment, fixture wear, and even micro-cracks in precision parts. For the injection molding of precision packaging parts (such as thin milk tea cups and milk tea cup lids), the discount technology ensures excellent product consistency and reduces downtime caused by vibration alarms. In addition, reducing mechanical stress extends maintenance intervals, lowers the full life cycle service cost, and improves uptime for high-end, high-precision industries.

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Servo drive and multi-axis standard bus design

Traditional linear robots or take-out robots usually use multiple dedicated drives, which cause problems such as equipment heating, complex wiring, and redundancy. Topstar’s 3 axis robot series adopts a five-in-one servo drive architecture, equipped with a multi-axis common bus, which can centrally distribute three-axis power. This design reduces electrical losses, reduces cable clutter, and supports regenerative braking, capturing kinetic energy during deceleration and returning it to the DC bus for reuse in subsequent acceleration phases. As a result, the system can be up to 20% more energy efficient, reducing the operating costs of production facilities. Combined with high-torque servo motors, the three-axis robot provides the dynamic performance required for fast injection molding cycles while maintaining a lean energy profile.

Special movements and high precision for packaging parts

The high-speed packaging industry often requires specialized post-molding operations directly in the molding cell. The 3 axis robot series supports various modular end-of-arm tools, such as heat staking for fixing inserts and in-line labeling for product identification, completing these tasks immediately after part ejection. The high-precision 3 axis robot maintains position repeatability within ±0.01 mm, ensuring it accurately places each packaging component for subsequent operations. For example, in milk tea cup production, a 3 axis robot can take out multiple cups, invert them to the rinsing station, stack them into crates, and then feed them into the filling line – all in the same cycle. This level of automation reduces cycle time and enhances quality control, resulting in a truly end-to-end automated high-speed packaging solution.

Improve efficiency in high-speed molding

The importance of 3 axis robots in the high-speed molding industry lies in their continuous production capacity, multi-track flexibility, vibration suppression, and energy-saving servo drive design, allowing manufacturers to meet seasonal order fluctuations and order surges while maintaining excellent quality and uptime. By integrating these linear robots into their molding lines, packaging companies can quickly scale up, ensure continuous production without interruption, and reduce the total cost of ownership.

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