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How to integrate the injection molding robot with the injection molding machine control system?

2025/09/17 By le zhan

How to integrate the injection molding robot with the injection molding machine control system

Integrating an injection molding robot with the injection molding machine control system transforms the two independent devices into a coordinated production unit, increasing output, improving part quality, and reducing cycle time variability. As an injection molding robot manufacturer, Topstar uses an open underlying control system architecture to enable the injection molding robot and injection molding machine to share a native “language,” making the device connection an extension of the control system rather than a fragile communication link.

This allows them to respond to host signals for integrated operation, automatically optimizing the removal process in real time during machine switching and the holding pressure phase, thereby improving injection molding efficiency on the production line. The system’s openness also provides significant operator convenience. Technicians can use a handheld teach pendant to modify program sequences, servo parameters, and mechanical parameters, or update application code to explore optimal automation strategies for new molds and processes.

Determining the Integration Architecture and Communication Protocol for Injection Molding Robot Operation

For injection molding robots, deterministic, low-latency interfaces with clear signal and data point mapping are preferred. Traditional approaches use hardwired discrete input/output (I/O) for safety-critical interlocking, while relying on fieldbuses or industrial Ethernet for high-level coordination. Topstar integrates a unified communication language and control system, making it open and accessible. This allows the injection molding machine to call robot functions through the same control system programming environment. This eliminates translation layers and simplifies program modifications.

For high-speed, tightly synchronized cells, EtherCAT or direct real-time Ethernet connections are preferred because they provide sub-millisecond determinism. In this configuration, the injection molding robot controller subscribes to the machine’s real-time tracking. This is particularly useful for advanced switching strategies based on cavity pressure. Instead of using a fixed screw position, the injection molding machine publishes measured cavity pressure, and the injection molding robot waits for a gating signal to initiate extraction, minimizing flash and ensuring consistent packing pressure.

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Injection Molding Robot Synchronization Strategies

Synchronizing the injection molding robot with the injection molding machine control system is a critical technical decision. Traditional systems use position switching, switching the press from velocity mode to packing mode at a preset screw position, then triggering the robot based on a timed delay or discrete “mold open” output. This approach works well for stable processes, but can become less stable when resin viscosity, ambient temperature, or mold wear alter the cycle dynamics.

Topstar’s pressure-based synchronization strategy uses in-cavity or nozzle pressure sensors to trigger switching and notify the injection molding robot when the cavity has reached the holding state and is safe for extraction. For example, when the control chart indicates a successful hold, the injection molding machine’s control system can issue a corresponding signal, and the robot then performs a precisely timed pick to avoid impacting the semi-cured part. Event triggers such as “First cavity gated,” “Filling complete,” or “Mold closed and locked” can then be displayed, and the robot executes the corresponding subroutine. Topstar’s open architecture allows operators to reassign or adjust these event triggers from the same human-machine interface, creating flexible sequences tailored to part geometry.

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Safety, Guarding, and Standards Compliance for Integrated Cells

Safety is an essential element when integrating an injection molding robot into a production cell. The robot and injection molding machine must provide consistent safety features to protect personnel while not unduly limiting production output. We begin with a comprehensive risk assessment based on ISO 12100 and apply relevant standards, such as ISO 10218 for industrial robots and ISO 13849 for safety-related control systems, as well as region-specific regulations.

We determine whether the cell will operate in guarded mode with fixed fencing, light curtains, interlocking doors, and a safety PLC, or in collaborative mode with speed and force limitations. For high-speed, high-volume production, guarded cells remain the standard, as they achieve the highest cycle performance while preventing human contact. Safety signals are integrated at the hardware and controller levels, ensuring the injection molding machine’s “safe move” state is interlocked with the robot’s safety-rated inputs, and that both devices use the same safety PLC or certified safety network instructions to enter the safe state.

Quality Inspection and Data-Driven Traceability

One of the key advantages of tightly integrating the injection molding robot with the machine control system is the ability to embed quality assurance directly into the process. Vision systems and in-process measurement capabilities enable the robot to perform orientation correction, presence checks, and basic dimensional inspections within the same cycle, reducing manual inspection and providing traceability for each part. A vision system enables the robot’s end-of-line automated tooling (EOAT) to pick up parts, bring them to a camera, and then maintain that position. At the same time, the machine or local processor performs inspection. In Topstar’s integrated architecture, inspection results can automatically trigger real-time process adjustments: if a cavity consistently produces parts that don’t meet specifications, the host computer can adjust the injection speed, holding pressure, or temperature setpoints to compensate, or it can initiate preventive maintenance procedures or mark the tool for cleaning.

Real-Time Synchronization, Automatic Optimization

Topstar’s open underlying control system addresses this issue by creating a native language for the injection molding robot and machine, enabling real-time synchronization, automatic optimization, and operator-friendly adjustments. Whether you’re an SME or a large injection molding manufacturer, this approach transforms integration from a challenge to a competitive advantage. By prioritizing an open architecture, manufacturers can achieve 15-25% efficiency gains, reduce costs, and adapt to future process changes, all while staying ahead of the curve in this rapidly evolving industry.

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