The Benefits of Linear Servo Robots…

FlexibilitySpeed

CapabilitySpace Savings

SimplicityCost Effectiveness

Injection Molding and Linear Servo Robots

X Y Z A B CX Y Z A B C

The Benefits of Linear Servo Robots…

All Robots share the same justification premise: To reduce costs for the manufacturer. Cost reduction examples:

Direct labor savingsQuality improvementScrap reductionCycle time reductionsValue added operationSafety improvement

But linear servo robots are unique in the world of robots as they are designed and built specifically for Injection Molding. The following are examples of Why linear servo robots are unique and How they benefit the injection molder.


Linear Servo Robot Benefits

The flexibility of the linear robot traverse beam for re-orientationallows molders to adapt from application to application quickly and easily on any side of the molding machine.

Flexibility…mechanical

From Operator side and Rear side discharge to T-Beam and Longitudinal-

Mount

Mechanical Re-Orientation Flexibility

RearRear

TT--BeamBeam LongitudinalLongitudinalOperatorOperator


Uniquely, Linear servo robots can handle parts on the operator side of the molding machine w/o removing safety gates.

Floor mounted type robots require rear entry with safety gate removal; front gate entry is not an option. But, floor mounted robots could be pedestal mounted from above or a 7th axis linear beam option could facilitate operator side work cell orientation.

Flexibility…and safety

Mechanical Re-Orientation Flexibility

Operator side parts handling

Picking parts from the mold and placing to the operator side is one of several standard linear

configurations



.

The linear servo robot can handle two sides of the molding press within each molding cycle by using a standard T-Beamconfiguration w/o the need and purchase of additional robots, servo axis or beams.

This linear configuration has excellent utility for molders…saving cost and

complication.

Flexibility…

Separate good product from rejects

Great use of space and quality control

TT--BeamBeam



Linear robots have the advantage of long reach and thus they are well designed to place parts at the clamp end of the molding machine.

Another benefit: Clamp end parts discharging saves space but also allows a value stream of finished product to flow down the main aisle when molding machines are aligned…a “trunk line” formation.

Flexibility…reach

E

Clamp-end parts release

Create a value stream flowCreate a value stream flow



Beware of “Over-Buying” the idea of Flexibility

With linear Servo Robots, molders do not have to purchase more axis of motion than they need to de-mold parts or perform secondary operations….because…

3 Servo axis of motion is all that is needed to get to any point in space (as shown) within it’s work envelope. 4 or more axis is only needed for more complex movements. Linear robots do offer up to 10 axis of servo control if needed.

Also note that the molding cycle governs how much flexible value added work can be done to demolded parts therefore if cycles are short than over-buying flexibility is more apparent.

Flexibility…

.

Only 3 axis are needed for a 3-D work envelope

Work Envelope



If Speed is what a molder needs then linear servo robots are the tool for the job…whether it is a high speed top entry or a high speed side entry, no robot is faster.

With it’s narrow profile, simple un-knuckled take-out motion, daylights stay narrow and cycle times short. Only 1 or 2 axis of motion are needed.

Speed increases Output and increased Output

improves ROI

Speed…the Top Entry

> Speed = > ROI> Speed = > ROI

Top Entry High Speed Linear Robot



Linear side entry robots are built with one thing in mind… Speed. ..for fast molding cycles.

For light weight low or high cavitation thin walled parts, the linear side entry can extract parts in less than a second in daylights under four inches.

The benefit of speed and simplicity of 2-3 linear axis.

Speed…the Side Entry.

>> Speed = Speed = >> ROIROI

Show Movie Clip of a W7X5HS side entry

Scara-robot here

.2s take.2s take -- out tim

esout tim

es ……

……

……

……

……

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....



IML: In Mold LabelingIML: In Mold Labeling

Now built for more Capability and Payload handling, linear side entry robots handle IML mold applications very effectively.

Speed…meets capability

High Speed IML: Stack mold label loading and part removal



Linear robots are more capable than ever. The linear robot now offers A/C articulated servo wrists for the most demanding de-molding and value added applications.

Now linear robots offer the benefits of both linear and 6 axis robots:

… long reach and the articulated wrist.

Best of both worlds

Capability…

Linear motion combined with articulated motion

Articulated A and B servo

wrist axis



Linear robots are more capable than ever. ..Why?…The linear robot offers CNC based controllers combined with easy programming to handle very demanding value added processes for the injection molder.

Secondary operationsDegatingSortingInsert loadingTote / Box loadingPalletizingIntegration for labeling, serial coding, bagging etc.

Capability…secondary operations

Systems Integration

Systems Integration …

……

……

……

……

……

……

…....

H

Metal Insert Loading



Linear servo robots have color high resolution control pendants that do much more than just axis control.

They combine the intuitiveness of color graphics yet have full CNC capability.

The pendant is not just focused on axis control but also offers useful operator and work cell information…

Capability…in control

AController Capability Controller Capability …

……

……

……

……

…....

Multi-Operator interfaces

Built-In Operation Manuals



Linear control capability and multi axis capability handles Pre-mold and Over-mold applications well.

Multi-mold structural foam machines and family molds are also easily handled.

Dual robot, single traverse beam: Z+Z+X+X+Y+Y plus two C posture axis (8 total axis of movement control)

Linear Servo robots are not limited to 3 servo axis of

movement!

Capability…special applications

Show pic one robot serving 2 machines

Capability above and beyondCapability above and beyond …

……

……

……

…....

Show pic of 743SO robotGreat for Structural Foam

Demolding

Pre-mold / Overmolding



Also…Linear robots are well designed to handle Stack molds and 3 Plate molds.

Stack mold de-molding is not so simple with other types of robots.

Capability…3 plate molds

Show pic 744D

Stack molds and 3 plate m

oldsStack m

olds and 3 plate molds ……


Linear Servo Robot BenefitsTwo Main Arms for Demolding

Three Plate Molds

With linear servo robots speed and payload is not a variable to be re-calculated from application to application…i.e. payload handling does not decrease with reach or speed increases.

The molder will not have to be concerned with changing robot payload handling capability as it’s reach is extended or it’s speed is increased.

Some non-linear robots often require considerations for Inertia / Moment-load as reach is extended or speed (and acceleration) is increased.

Capability…and constantsMoment of Inertia

T=(mr^2)*A

Linear robots: the payload handling is the payload handling…simple.

linear motion is not this complicated



Though linear robots can handle the majority of molders needs there are many applications that 6 axis articulated robots are specifically suited for:

• Edge Routering / Material Removal• Painting / Dispensing• Welding / Laser• Complex assembly• Palletizing

Note also: The 6 axis and Scara type robot can make a great work cell companion to the Linear robot for special secondary applications.



Linear robots, being platen mounted and not floor mounted, do not occupy the work envelope that they need to do value added operations…thus they require less floor space and allow the molder free access to the side of the mold.

Also linear robots have a “Square”work envelope which nicely matches the geometry of a molding machine and the space between molding machines i.e. typical floor plans of molding shops.

Linear robots fit “tightly” in molders production areas.

Space Savings

.

.D

“Square Foot-print and Square Work-Envelope Space” fits well in molding shops

Not a lot of extra room between presses



Linear robot systems are mobile. A great advantage versus floor mounted robots because only the conveyor or secondary equipment “sits” beside the press.

Molders can Simply “Roll” the work cell away for unrestricted mold access and maintenance.

3-5 axis Linear robots fit “tightly” in molders production areas.

Space Savings…and mobility AnceUn-encumbered space for easy mold access

Roll-Away work cell



These days most linear robots do not have a large floor mounted controller wasting space.

They have robot mounted controllers and press mounted pendants…this saves space: 2-4 cubic yards per molding machine.

3-5 axis Linear robots fit “tightly” in molders production areas.

Space Savings… is a premium

Space saving beam mounted controller

Large floor space needed

Linear robot controller…

beam mounted

Typical 6 axis robot controller

PicPic of robot mounted of robot mounted controller herecontroller here



The “easiest” distance between 2 points is not a compound-knuckled multi-axis motion but rather 1 or 2 axis “straight” line.

Molders embrace Linear robots super-simple graphic point-to-point teaching.

Simplicity…to teach Graphic showing a simple take out sequence in line form

Simple is Good



Simple and Easy Installation and quick on-site operation training.

From crate to production in 1 or 2 days is common; no other robot for molding can do this. This is the benefit of a Linear Servo robot type that is designed specifically for molding.

Simplicity…to implement

.

From crate to production in 1 or 2 days

Day 1

Day 2



Simple and Easy to Teach and Program…this is a benefit of inherently easy-to-understand linear control combined with powerful graphics.

Linear servo robots also have plenty of control “horsepower” for the most demanding of applications with it’s CNC step-by-step programming.

Simple when the molder needs it, powerful when the molder needs it:

the best of both worlds.

Simplicity…in learning curveGraphicsGraphics

StepStep--byby--stepstep



Linear robots typically have the excellent graphical based controllers.

From operators to technicians to engineers…more of the plant personnel are empowered to keep the robot running, optimized and re-implemented …thanks to the ease and power of linear graphical interfaces.

Simplicity…in Graphics



Price: Linear Servo Robots are at the greatest value in their history. They are faster, easier to control, super capable and very flexible at pricing that barely purchased a low cost pneumatic robot not long ago.

They typically are lower priced than other Non-linear robots and do not have a long learning curve or costly training requirements.

Cost Effectiveness$$

Linear

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Linear Pricing VS Articulated Pricing

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Linear

Don’t call them “Pickers”

Linear servo robots are not just basic “Pick-n-Place” robots. They now have great…

FlexibilitySpeed

CapabilitySpace Savings

SimplicityCost Effectiveness

Performance meets Cost Savings;the very thing competitive molders need.



Resources

Article (pricing reference for 6 axis robots see slide #24): State of the Tech: High-tech articulated robots for the masses; Oct 2006; by Rob Neilley; Injection Molding Magazine; ABB data

Content: Slides, pictures, graphs, animation, text: Wittmann Inc.; Author Joe Varone; 5-08


Documents

The Benefits of Linear Servo Robots…