+86 17727725162 jqj014950@topstarltd.com

Home / Why can Topstar’s EU series injection molding robots improve overall production efficiency?

Why can Topstar’s EU series injection molding robots improve overall production efficiency?

2026/02/20 By le zhan

injection molding robots 4-3

In Topstar’s injection molding robots series, the EU series is not simply an injection molding robot, but rather a system designed to improve molding efficiency throughout the entire injection molding production process. It shortens cycle times, stabilizes downstream operations, and reduces energy consumption per part. Topstar optimizes motion control and mechanical dynamics by combining AC servo drives, DC bus energy management, and a lightweight A6061 robotic arm, resulting in faster robot response, lower energy consumption, and reduced maintenance requirements.

AC Servo Technology in Injection Molding Robots: Achieving Both Precision Motion and Energy Efficiency

AC servo technology is the core control technology of Topstar’s EU series injection molding robots. Unlike traditional DC motor systems, modern AC servo systems provide high-resolution position feedback, faster control loop response speeds, and a higher torque-to-inertia ratio. These characteristics allow the injection molding robot to achieve clearer motion trajectories and more precise path tracking when working in conjunction with the injection molding machine.

In addition to superior motion accuracy, the AC servo system also supports advanced energy-saving algorithms. Topstar’s motion controller utilizes regenerative braking and torque-optimized trajectories to reuse or transfer the energy recovered during deceleration to the DC bus. Therefore, the motor only consumes current when it needs to overcome load or gravity. The combination of high precision and intelligent energy routing in the servo system reduces the net energy consumption of the injection molding robot during continuous operation, especially in the frequent pick-and-place cycles common in injection molding production lines. This directly reduces the power consumption per part and reduces the peak power demand on the factory’s electrical infrastructure. Furthermore, smoother motion curves reduce the mechanical shock transmitted to the injection molding machine during part transfer, thus reducing the risk of clamping interference and injection weight drift.

AC Servo Injection Robots

DC Bus Technology in Injection Molding Robots: Reducing Energy Consumption by 10%

One of the key architectural choices in the EU series is the adoption of DC bus technology. In this design, multiple servo drives share a common DC link for storing and distributing regenerative energy. In a typical injection molding robot operation, the robot repeatedly accelerates and decelerates in each cycle, and the braking phase generates a significant amount of kinetic energy. The DC bus captures this energy and redistributes it to other drives that require immediate power, instead of dissipating it as heat through braking resistors. This architectural change delivers significant energy savings.

Topstar’s internal testing and field data show that EU series injection molding robots consume approximately 10% less energy compared to similar robots using a resistive braking isolated drive architecture. The energy savings are particularly significant in high-load cyclic operating conditions such as injection molding: for example, short cycles, frequent starts and stops, and repetitive pick-and-place movements. Therefore, the EU series DC bus design provides immediate energy savings and reduces infrastructure and maintenance costs in the long run, all of which directly contribute to increased production efficiency.

DC Bus Technology in Injection Molding Robots

Lightweight A6061 Robotic Arm: Faster Response and Higher Throughput

Mechanical design is just as important as electrical design. Topstar uses A6061 high-strength aluminum alloy in the EU series injection molding robot arms, achieving an optimal balance between rigidity and lightweight design. Compared to traditional steel arms, the A6061 structure reduces moving mass and inertia, allowing the AC servo motors to control the arm’s acceleration and deceleration more quickly and precisely. As a result, the maximum speed of the EU series injection molding robot arm is increased by approximately 10%, and the acceleration and deceleration time is reduced by approximately 20%.

These dynamic improvements directly impact the injection molding machine’s cycle time, as the injection molding robot‘s movement is often on the critical path. Faster arm movement reduces the time spent on non-processing parts of the cycle. A 20% reduction in acceleration and deceleration time allows the robot to reach the required speed and stop with less dwell time, enabling the injection molding machine to start the next cycle faster. Furthermore, lower inertia reduces the stress and energy required for motion reversal, thus reducing cumulative wear on bearings and joints and minimizing high-torque events that could disrupt the injection molding unit. From an operational perspective, a lighter and faster injection molding robot can complete more handling cycles per hour without sacrificing payload capacity or positioning accuracy. For manufacturers, this means higher effective output per injection molding unit and higher overall equipment effectiveness (OEE).

A6061 high-strength aluminum

Motion Control and Algorithm Optimization for High-Speed ​​and Precise Molding

Topstar combines hardware improvements with advanced motion control algorithms, enabling EU series robots to achieve higher average speeds while maintaining positioning accuracy. These control strategies minimize overshoot and reduce the conservative speed limits that traditional injection molding robots must set to avoid vibration or part damage. In practical applications, injection molding robots can operate at near-peak speeds and perform complex motion path operations, such as removing parts from small cavities, adjusting the orientation of fragile parts, and placing them in narrow discharge chutes.

When energy-saving algorithms are combined with motion planning, the injection molding robot controller uses predictive models to calculate the most efficient torque commands to follow a preset path. These predictive models consider factors such as payload, center of gravity offset, and joint friction. More importantly, the motion control system is integrated with the injection molding machine’s cycle signals, allowing it to predict machine status. This synchronization reduces idle time: the robot arrives at the mold precisely when needed, avoiding energy waste from prolonged standby.

Increased Production Efficiency in Part Handling and Mold Transfer

The EU series significantly improves the production efficiency of common robotic tasks in injection molding operations, including product handling, insert positioning, in-mold assembly, and mold transfer. In product handling, the combination of speed, repeatability, and shorter cycle delays means more parts can be removed and packaged or further processed per unit of time. Higher acceleration reduces cycle times for parts with short cooling windows, allowing the injection molding machine to start the next cycle faster without compromising part quality.

For handling large plastic parts, the lightweight robotic arm and high-strength A6061 aluminum alloy structure provide better dynamic stability during motion and mold changes. Faster acceleration and deceleration speeds mean faster mold changes and shorter mold change downtime. Furthermore, the EU series injection molding robots can work collaboratively with auxiliary equipment, such as robots transporting parts to auxiliary workstations or conveyors, because their control system supports precise timing and networked I/O signals that can be integrated with the injection molding machine controller. These advantages improve overall production efficiency in injection molding, resulting in lower production costs.

Improved Overall Production Efficiency

Topstar’s EU series injection molding robots are not just auxiliary equipment, but strategic productivity tools that enhance the overall performance of the injection molding machine and the entire production unit. By combining AC servo technology, DC bus energy-saving architecture, and lightweight, high-strength A6061 robotic arms, the EU series injection molding robots offer faster response times, higher operating speeds, and approximately 10% lower energy consumption compared to traditional injection molding robots. These advantages translate directly into shorter production cycles, lower operating costs, greater process stability, and higher energy efficiency per unit of output. Whether used for high-speed product handling, mold transfer, or integrated automation systems, the EU series injection molding robots help manufacturers achieve more efficient and competitive injection molding production.

 

 

Prev: Why can Topstar dehumidifying dryer provide a stable low dew point for injection molding?

Next: 24-hour timer function: Topstar cabinet dryer can achieve timed drying

TRENDING POSTS

HOT TOPIC

Get A Quick Quote