Industry 

The customer was able to win the order for the complex injection moulded component. A fully automated solution had to be developed so that economic production was possible.

Initial situation

In order to be able to produce very long injection moulded parts with a total of 27 inserts for the automotive sector, an SGM automation system was developed and built. The two different insert types are fed via spiral conveyors, picked up by the robot gripper on the ABB industrial robot and inserted into the 2-cavity mould. The same robot gripper is used to pick up the finished injection-moulded individual parts with vacuum and place them on the inspection station. The inspection station checks that the insert holes have not been overmoulded and inductive sensors check that all 54 inserts are present in both parts. The 180° turned injection moulded parts are traded to the screw assembly station by the robot. At the two screw assembly stations, a total of 34 screws are fed in and pressed in.
When all processes have been successfully completed, the injection-moulded part is marked with a label (2D matrix code) and output to the operator via a conveyor belt.

Solution

- High degree of automation. - The operators are only responsible for refilling inserts and removing parts from the conveyor belt. 
- High quality control - Via image processing, the customer can be sure that the quality of the injection moulded parts meets the high requirements.
- Highly automated processes - No manual effort for pressing in the screws
- Short cycle times

Advantages customer

The customer can use this new automation system to produce plastic injection moulded parts with 54 inserts for the automotive sector.

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Feeder 

Handling + Gripping 

Marking

Testing 

Support plate

Screw assembly station: Before the screws are pressed in, a vision system checks where the relevant hole is located. Then the shuttle and the setting head move to the correct position and the screw is pressed in.

Screw assembly station

The Scara robots pick up the height-checked inserts from the bowl feeders and place them on one of the two transfer shuttles.

Scara robot

In the foreground, the two Scara robots can be seen, which supply the inserts to the transfer shuttles. In the background, the 6-axis robot can be seen, which both collects the inserts and handles the finished injection moulded parts to the various stations.

Carrier plate for the automotive industry

Automation

Unternehmen