What are the application scenarios of three-axis injection molding manipulator?

Full Analysis of Core Application Scenarios of Three-axis Injection Molding Manipulator

Three-axis injection manipulator (X-horizontal+Y-vertical servo drive+Z-vertical servo drive) is the most popular and cost-effective automation equipment in the injection molding industry, with positioning accuracy of ±0.1mm, which is suitable for a full range of horizontal injection molding machines with 50-4,000 tons. The core solution is to meet the automation requirements of taking out, handling and auxiliary processes of injection molded parts, and it is the standard for injection molding plants to realize "machine substitution". The core application scenarios are as follows:

First, the core characteristics of three-axis injection molding manipulator (the basis of adapting to the scene)

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Adaptability value of specific advantages of core characteristics

The cost of high performance-to-price ratio is only 50%-70% of that of 5-axis/6-axis manipulator. Small and medium-sized injection molding plants can quickly land for mass popularization, and the return period is 6-12 months.

The efficient and stable take-out cycle is the fastest 2-3 seconds, and it runs continuously for 24 hours. The yield is more than or equal to 99.5% instead of labor, which solves the problems of difficult recruitment and low labor efficiency in the injection molding industry.

The positioning accuracy of the servo drive with controllable precision is ±0.1mm, so as to avoid manual picking and bumping. The product is suitable for injection molded parts with high precision and high appearance requirements.

Flexible function and customized fixture can realize multi-action covering the whole injection process of taking parts, cutting water, stacking, embedding and labeling.

Strong adaptability, compatibility with most horizontal injection molding machines, simple installation and low operating threshold. Both old injection molding machines and new injection molding machines can be used.

Second, the core application scenarios (by industry)

1. General injection molding (the most basic application, accounting for over 60%)

Specific application: automatic take-out, blanking and stacking of all ordinary regular injection parts, such as plastic fittings, shells and structural parts.

Adaptation advantages:

Instead of manual mold opening and taking parts, it solves the recruitment problem of high temperature, high humidity and repetitive labor in injection molding workshop

A single manipulator can adapt to one injection molding machine, which can produce continuously for 24 hours, and the production capacity can be increased by more than 30%.

Avoid manual picking, avoid collision and leakage, stabilize product yield, and be suitable for general automation upgrade of all small and medium injection molding plants.

2. Consumer electronics industry

Specific applications: mobile phone shell, charger, data cable connector, computer accessories, earphone shell, smart home appliance shell pick-up, water cut, plate setting.

Adaptation advantages:

Take parts with high precision, avoid damaging the appearance surface and high gloss surface of electronic parts, and ensure the appearance yield of products.

Fast speed, short-cycle production with high-speed injection molding machine, suitable for mass production of electronic parts.

With the fixture, the nozzle can be automatically cut and the electrostatic dust can be removed, which reduces the back process and realizes the integration of injection molding and back process.

3. Household appliance manufacturing industry

Specific applications: taking out, carrying and stacking plastic panels, buttons, interior parts and shells of air conditioners, washing machines, refrigerators and small household appliances.

Adaptation advantages:

It can carry 5-30kg of plastic parts of medium and large household appliances, replacing manual handling, reducing labor intensity and avoiding work-related injuries.

High stability of mass production, large batch of household appliances, 24-hour operation of the manipulator, stable and controllable production capacity.

It can be connected to the assembly line, and directly transported to the assembly line after being taken out, so as to realize seamless connection between injection molding and assembly.

4. Auto parts industry

Specific application: taking out and burying automobile interior trim (door panel, instrument panel fittings, central control trim panel), exterior trim, engine plastic fittings and wiring harness connectors.

Adaptation advantages:

Strong load capacity, can carry 10-50kg of automobile injection parts, and solve the problem of heavy manual handling.

The positioning accuracy is high, and the automatic embedding of nuts and metal parts in the mold is realized by matching with the fixture, which replaces the manual embedding, and the efficiency is improved by more than 50%.

High production consistency, high requirements for yield of automobile parts, stable picking of parts by mechanical hand, and avoidance of scrapping caused by human error.

5. High-speed packaging/thin-walled products industry

Specific applications: plastic lunch boxes, milk tea cups, bottle caps, food packaging boxes and disposable tableware are taken out, stacked and packed at high speed.

Adaptation advantages:

Ultra-high-speed take-out, the fastest cycle is 2 seconds, and with the high-speed thin-walled injection molding machine, high-speed mass production of one mold and multiple cavities can be realized.

Stack neatly, automatically stack and palletize according to the quantity after taking out, and directly butt-joint the packaging process without manual sorting.

Food-grade production, the manipulator takes parts without contact, avoiding manual pollution and meeting the hygienic requirements of food packaging.

6. Medical consumables industry

Specific applications: syringes, infusion set accessories, blood collection tubes, medical plastic shells, taking and setting plates of testing consumables.

Adaptation advantages:

Clean production, the manipulator picks up the parts without contact, which avoids the pollution caused by manual contact and meets the requirements of GMP medical clean production.

High precision, small size of medical consumables, high precision requirements, accurate picking by manipulator, no collision and deformation.

Can be connected with a clean assembly line, and directly enters the disinfection and packaging processes after being taken out, so as to realize aseptic production in the whole process.

7. Commodity/toy industry

Specific application: taking out and sorting plastic pots, barrels, clothes hangers, toy shells, stationery and household plastic parts.

Adaptation advantages:

The cost is low, which is suitable for the low-profit and large-scale production needs of the daily necessities industry and can be quickly recovered.

Instead of labor, the daily necessities industry has high labor cost and high mobility, and the manipulator is stable in production, reducing management costs.

It can realize the quick sorting of one mold and multiple cavities, and automatically classify products with different cavities, thus reducing the subsequent labor.

8. Special injection molding process scene

In-mold embedding: automatically embed nuts, metal parts and terminals into the mold to realize the integration of embedding-injection-removal, which is suitable for injection-molded parts with metal inserts.

In-mold labeling: with the labeling fixture, the label is automatically put into the mold, which realizes injection and labeling at one time, and is suitable for in-mold labeling of packaging boxes and containers.

Two-color/multi-color injection molding: cooperate with two-color injection molding machine to complete the removal and transposition of plastic parts with different colors, and realize the automation of multi-color injection molding.

Third, comparison of selection and inapplicable scenarios

Compare the advantages of other manipulators.

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Comparison type Three-axis injection molding manipulator adaptation scenario Other manipulator adaptation scenarios

High-end injection molding of inclined arm manipulator, high precision, simple and small scenes requiring auxiliary technology, low cost and only basic parts taking.

Five-axis/six-axis manipulator has regular shape injection parts, picking parts and simple auxiliary technology, and pursues special-shaped parts with complex cost performance, complex actions requiring overturning/multi-processes, and super-large parts.

Inapplicable scenario

Super-large injection molded parts (single weight > 50kg) need a heavy-duty five-axis/truss manipulator.

Complex special-shaped parts need multi-axis turning and multi-angle picking.

Multi-process complex integration (such as taking parts+grinding+assembly integration) requires a six-axis joint manipulator.

summary

Three-axis injection manipulator is the first choice for general automation in injection molding industry, covering more than 90% of conventional injection production scenes, especially suitable for injection molding plants with large batch, regular shape and requirements for cost performance, and it is the entry standard for automatic upgrading of injection molding workshops.