Automated manufacturing cells for sustainable injection moulding quality

During the last few years, injection moulding processors have shown increased interest in electric injection moulding machines (eIMM) with, on the one hand, their high energy economy and awareness of fully automatic production systems on the other. At Fakuma 2012 (Hall B3, Stand 3211), FANUC Robomachine Deutschland GmbH is featuring three electric ROBOSHOT IMMs, thus seamlessly staying abreast of emerging user demands. In the live demonstration, a 30-ton ROBOSHOT, integrated into a fully automatic manufacturing cell, will be producing highly precise miniature components (gears for watches) by micro injection process. In addition, visitors can obtain information about economic production of two-component parts (ice scrapers) on a 150 ton ROBOSHOT machine. Responsible for the second component, is a Mould-Masters E-Multi injection unit. Finally, a new 100-ton ROBOSHOT Alpha-S-100iA – with a more powerful control system – will produce components for protective helmets precisely and highly economically.  

“These three applications show a cross section through the FANUC ROBOSHOT performance “, says Sales Manager Rainer Zerr and explains “…with energy recovery control, stable repeatability and process security, Precise Metering Control – PMC 2 and 3 – and Backflow Monitor as well as the efficient AI mould protection. Last but not least, we demonstrate together with our systems partners, economic and technical competence in the areas of two-component injection moulding and manufacturing cells with high flexibility.”  

On a FANUC ROBOSHOT S-2000i-30B (300 kN clamping force), micro parts – tiny cog wheels for watch movements – are being produced. A 6-axes robot, FANUC LR Mate 200iC, including a visual inspection system supplied by systems partner ROBOTEC, removes and deposits the finished components. Result: 100% visual inspection of both sides of the parts, consistent parts weight of 0.004

The coordinated cooperation with Mold-Masters Europa GmbH proves to be flexible and economic in conjunction with two-component applications. A FANUC ROBOSHOT S-2000i-50B (500 kN clamping force), operating with an E-Multi as second injection unit, is complemented with an integrated rotary drive and a flexible injection unit support. The two-component mould, supplied by POLAR-FORM Werkzeugbau GmbH, Lahr, Germany, produces ice scrapers in PS and TPV. Part extraction and printing is accomplished by a FANUC industrial robot in the manufacturing cell designed by systems partner MARTIN MECHANIC.

New! Integrated and synchronized material supply into the IMM feed zone: this ensures optimum material venting. Bicycle helmet components for inside diameter setting are made in POM in a two-cavity mould supplied by DHG Knauer: part shot weight is 24.3g. Products such as these must adhere toAir Max 2018 KPU