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What key efficiency improvements can Injection Robots achieve?

2024/11/27 By Topstar

Injection robots 1-1

Injection robots automatically place and grab plastic parts instead of performing manual tasks. Doing so helps simplify injection molding production lines, shorten cycle times, minimize human errors, and increase production. They improve the precision and consistency of molded parts, save more energy, and improve workplace safety. As one of Topstar’s self-developed and self-produced products, the injection robot has come to the fifth generation, the five-in-one servo injection robot. So, in this article, we will introduce you to the critical efficiency improvements they can achieve.

The energy efficiency of the injection robots has increased by 20%

Every stop and collision of the machine will incur high costs, significantly reducing the energy efficiency of production. Therefore, Topstar has achieved a more precise, energy-saving, and intelligent “five-in-one” servo drive based on upgrading the underlying technical architecture of software and hardware. “Five-in-one servo drive” enables one servo drive to control 5 servo motors directly, and the removal control is more precise. Only 3 CPU chips are used to achieve a five-axis-in-one design. Each CPU chip controls two axes, and the maximum power of each axis is 750W. This provides mighty power for the injection robot. At the same time, the multi-axis standard busbar design scheme improves energy efficiency by 20%.

Injection robots 1-1

Increase production efficiency by 5% for each injection molding unit.

Traditional injection robot management aims to achieve cross-system interconnection through network protocols, which have signal delay, poor compatibility, and low stability. Topstar uses the open architecture of the underlying control system to enable injection molding peripheral auxiliary machines and injection molding machines to have a native language for system integration, making equipment interconnection an extension of the system. This can enable the injection robot to support the host to call signals, realize integrated operation, and allow the control system to automatically optimize the removal process, thereby improving the injection molding efficiency of the production line. It solves the problems of removal failure and equipment alarm shutdown caused by ejection position deviation and uncoordinated suction time. The injection robot and the mold opening process are synchronized, which increases the production efficiency of each intelligent injection molding unit by about 5%.

Injection molding unit 1-2

Enhanced the expansion and flexibility of the injection robots

Under the five-in-one servo drive system, the injection robot has more robust functional scalability and can add back-end automation processes according to customer needs. The robot’s back end can customize according to specific production requirements, whether it integrates quality inspection, classification, packaging, or additional material handling. This scalability ensures manufacturers can adapt to changing market demands without purchasing new robot systems.

At the same time, advanced manipulator motion control technology ensures smooth and precise movement according to predetermined contours when executing complex trajectories or paths. This flexibility’s efficiency improvement means a shorter production cycle, which shortens the turnaround time and increases the output, greatly improving the workshop’s production quality and efficiency.

Lighter weight and faster speed

The injection robot uses an arm of lightweight and high-strength A6061 material, reducing 20 structural components and weight by 20%. This makes the robot more flexible without affecting strength. Therefore, it is lighter and more capable of handling heavy tasks. The high-strength aluminum material ensures that the robot can withstand the pressure of rapid acceleration and deceleration without the risk of deformation or wear, thereby extending its service life. Weight reduction is also a great help in improving performance, especially speed and efficiency. Their maximum speed has increased by 10%, allowing the system to complete tasks faster without sacrificing accuracy. In addition, the time required for acceleration and deceleration has also been reduced by 20%, enabling faster start and stop of its actions.

Safer operation

The injection robot protection technology (soft floating joints) dramatically improves the robot’s ability to handle unexpected situations. This technology detects when the robot experiences excessive torque or strain, allowing the system to respond automatically by softening the movement or adjusting the torque level. This significantly improves the protection capability when facing torques exceeding the set torque, effectively reducing potential damage to customer molds, injection molding machine ejectors, and products and further improving production efficiency and equipment stability.

Injection molding robots operate more safely

At the same time, the optional “personnel protection configuration” reduces the risk of accidental injury due to unintentional contact with the running machine. This configuration provides additional safety protection for workers. It includes built-in sensors and safety barriers that detect whether there are human operators near the robot’s operating area. If the operator is too close to the robot, the system will immediately stop the robot’s movement to reduce the risk of accidental injury.

Comprehensively improve the efficiency of injection molding production.

Based on the “five-in-one” servo drive, the injection molding robot’s energy efficiency, production efficiency, expansion, and flexibility have been greatly improved. By automating key processes, these injection robots can improve productivity and promote safer and more sustainable operations.

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