Injection moulding high-quality parts

Injection moulding techniques have achieved tremendous improvements owing to the rapid technological modernisation and cooperation between machinery builders and their customers. These factors have made possible the production of high-quality parts required by various industries.

Automated manufacturing cells for sustainable injection moulding quality have placed emphasis on the role of electric injection moulding machines in the quest for sustainable production processes without sacrificing quality and efficiency. In the past few years, injection moulding processors have shown increased interest in electric injection moulding machines with the capability of being integrated into an automated manufacturing cell.

At Fakuma, Fanuc Robomachine Deutschland GmbH featured its three electric Roboshot injection moulding machines, thus seamlessly staying abreast of emerging user demands. A 30-tonne Roboshot, integrated into a fully automatic manufacturing cell, produced highly precise miniature components (gears for watches) by micro injection process.

Economic production of two-component parts (ice scrapers) was also presented via a 150-tonne Roboshot machine. Responsible for the second component, is a Mould-Masters E-multi-injection unit. Finally, a new 100-tonne Roboshot Alpha-S-100iA – with a more powerful control system – produced components for protective helmets precisely and highly economically.

“These three applications showed a cross section through the Fanuc Roboshot performance 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 demonstrated together with our systems partners, economic and technical competence in the areas of two-component injection moulding and manufacturing cells with high flexibility,” Fanuc Sales Manager Rainer Zerr explained.

Micro-injection moulding applications
On a Fanuc Roboshot S-2000i-30B (300 kN clamping force), micro parts – tiny cog wheels for watch movements – were produced. A 6-axes robot, Fanuc LR Mate 200iC, including a visual inspection system supplied by systems partner Robotec can remove and deposit the finished components. This resulted to 100 percent visual inspection of both sides of the parts, consistent parts weight of 0.004 gram POM, accurate product dimensions (outer diameter = 3.2 mm, shaft diameter = 0.3 mm), and weights that are within the range of tolerance, i.e. +/- 0.2 percent.

The coordinated cooperation with Mold-Masters Europa GmbH proves to be flexible and economic in conjunction with two-component applications. A 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.

A new integrated and synchronized material supply into the IMM feed zone 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 to stringent safety standards. These parameters require a very high process stability and reliability. The fully electric Roboshot injection moulding machine complies 100 pAir Max Shox 2018