How to choose the special manipulator for injection molding according to the processed products?

The core of choosing the number of axes of the special manipulator for injection molding is to look at the complexity of product taking out, whether it needs attitude adjustment, mold type, accuracy and beat requirements, and then match the functional boundary of single/two/three/five axes.

First, define the core functions of each axis (decide what to do)

The number of common axes of injection molding manipulator: single axis, two axes, three axes and five axes. The more the number of axes, the higher the degree of freedom and the more complicated the action.

Single axis (1 axis): only one servo axis (mostly horizontal/vertical), and the rest cylinders are driven; Can only do simple straight line pick and place, no attitude adjustment ability.

Two axes (2 axes): horizontal+up and down servo, pulling and pulling cylinders; Can be simply stacked and quickly picked up, without rotation/lateral posture.

Three-axis (3-axis): X (horizontal) +Y (front and back/pull) +Z (up and down) full servo; Three-dimensional linear motion, embedded inserts, in-mold paste, simple stacking, no rotation attitude adjustment.

Five-axis (five-axis): three-axis foundation+A (rotating around Z) +B (rotating around X) /C axis; It can rotate at any angle, pose sideways, turn over and take parts in complicated paths, and is suitable for three-plate die, overlapping die, insert and multi-station.

Second, according to the product and process selection (directly corresponding to the number of shafts)

1. Single-axis/two-axis: Minimal parts and low cost.

Applicable products: small simple parts (bottle caps, plastic cups, fast food boxes, thin-walled small parts); Just take out and put the conveyor belt/box in a straight line, without attitude adjustment.

Technology: two-plate die and hot runner die; Fast cycle, large batch and low cost automation.

Selection conclusion: single axis (mainly cylinder) → two axes (servo+cylinder), which can meet the requirements of quick picking and simple stacking.

2. Three axes: mainstream and universal, satisfying most scenarios.

Applicable products: conventional shells, plates, household appliances/daily necessities shells; It needs accurate parts picking, embedded parts, in-mold sticking, automatic packaging and multi-hole mold picking.

Technology: two-plate mould is the main one; It is required to repeatedly locate 0.1 ~ 0.2 mm, stabilize the beat and connect the simple automation line.

Selection conclusion: 90% conventional injection molding products prefer three axes to balance cost and function.

3. Five axes: required for complex products/processes.

Applicable products:

Special-shaped parts, parts with inverted buttons/deep cavities (rotating demoulding is required);

Insert products (nuts, metal parts embedded+angle adjustment);

Two-color/multi-color, overlapping die, three-plate die (main arm taking+auxiliary arm water intake);

Products (automobile parts, medical parts, 3C housings) that need to be turned over, sideways, rotated 360 degrees, transferred at multiple stations and stacked with high precision.

Technology: three-plate mold, overlapping mold, insert injection molding and in-mold assembly; It requires repeated positioning of ±0.05~0.1mm, complicated path and high flexibility.

Selection conclusion: complex product/complex process is the only choice, five axes = three axes+rotational freedom.

Third, the judgment dimension of key selection (quick decision)

Action complexity

Only linear pick and place → single/two/three axes

Need to rotate/flip/pose/complex path → five axes

Mould type

Two-plate die → single/two/three axes (single arm)

Three-plate die/overlapping die → five-axis (two arms, main intake+auxiliary intake)

Accuracy and beat

Ordinary precision, regular beat → three axes

High precision (within ±0.1mm), high speed/complex beat → five axes

Product characteristics

Small simple parts → single/two axes

Medium-sized conventional parts → three shafts

Large/Special-shaped/Insert/Multicolor → Five-axis

Automation integration

Pick-up only → three axes

Picking+Inspection+Assembly+Packaging → Five-axis

Four, the selection of quick look-up table (direct control)

form

Typical process cost of typical products with shaft number core competence

Single-axis straight-line take-and-place of bottle caps and small parts, two-plate die, low speed take-out

Two-axis straight line+simple stacking of fast food boxes, high-speed removal of thin-walled parts, and low stacking.

Three-axis three-dimensional straight line+embedded parts/labeling household appliances shell, daily necessities two-plate mold, in-mold paste, embedded parts

Five-axis three-dimensional+rotation/lateral posture/turnover automobile parts, medical parts, insert three-plate die, die stack, insert and multi-station height

V. Summary of Selection Steps

Make clear the product: size, weight, shape, whether it is embedded/inverted/deep cavity.

Make clear the process: picking action, stacking/rotating/embedding parts, and mold type (two plates/three plates/overlapping mold).

Clear requirements: accuracy, beat and degree of automation integration.

Number of matching axes: simple → single/two axes; Conventional → triaxial; Complex → five axes.

Verification: load, stroke and tonnage of injection molding machine are matched, and 20%~30% allowance is reserved.