Molding Automation Information

Innovative Gripper Technology

In almost every application, the weight of the plastic parts is insignificant compared to the removal gripper. The payload of a high cavity medical or packaging application can be less than 100 grams. Therefore, the limit of the speed lies in the design of the "end of arm" removal gripper. The use of lightweight materials such as carbon fiber allow for acceleration rates to create the world's fastest robot. It is essential that the system can verify that the parts have actually been removed from the mold each and every cycle. If a part remains in the mold upon closing, the resulting damage will surely lead to expensive mold repair and unplanned downtime. The key is to provide the necessary level of technology in a robust design for maximum efficiency.

Patented Drive Technology

Cycle times of less than 7.5 seconds are the domain of the high speed side entry robots. These are by nature very demanding due to the need for extremely precise positioning combined with the need for high acceleration and deceleration of the removal motions. Optimization of floor space is one of the key to the financial justification of the automation investment and the ability to improve cycle time compared to free fall parts is a must.

Robust Design

High speed operation of anything is demanding but to achieve this on a 24/7 basis is another thing altogether. Some manufacturers use lightweight aluminum components for the machine frame as the feel that "all it needs to do is hold the robot arm up". The fact is, the enormous energy which results from the change in speed is transmitted through the frame and must be dissipated. The frame is the conduit for the transfer of energy and without a robust frame design; precise alignment over the long term would be compromised.

Financial Feasibility

Investments are always measured in payback and the justification has its foundation in efficiency. Efficiency in turn can be seen as the best possible output with the absolute minimum of unplanned downtime. First, the output is related to the cycle time and the shorter the better. Virtually every application in the high speed arena requires mold open time shorter than a free falling part. The next element is to reduce scrape rates by reducing start-up time and maximizing cavitation. In a multi-cavity application, the reality of production is that occasionally one or two cavities will run out of tolerance. The ability to shut off a single cavity and continue producing is the difference between unplanned downtime and over 98% efficiency. The ability to formulate and carry a logical repair plan will greatly enhance the payback and justification of the investment.

Solutions for Demanding Markets

Medical and packaging are but two of the key market segments which always have a high demand for performance. Applications such as pipettes have elements of both. For example, this application runs a 64 cavity mold at under 3.5 seconds in a clean room environment. Integrity is maintained including the assembly of the filter inserts and packaging in trays according to their cavity number. The key to success is the combination of know-how, experience. The definition of world class is those same criteria but with innovation included. After all, only being as good as everyone else is the very definition of mediocre.