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 by Mr. Dipl.-Ing. (FH) Hubert Jäger founded JÄGER-Engineering and converted into a GmbH 

 . Special machines and production cells have been built since September 

 One focus here is the development of intelligent low-cost production systems (LCIA /LCIP®) based on FANUC and SIEMENS controls.

The first LCIP machine concept was delivered in September 

 for a large automotive supplier from the region. The first training courses on the topic (LCIA /LCIP®) took place in September 2013. The next current training courses can be requested.

As a medium-sized company with headquarters in Königsfeld near Villingen-Schwenningen, we have regional roots and are internationally networked as a long-standing partner of leading companies. The basis for this: trust, reliability at all levels and the willingness to realize visions together.

Flexmaster Pro | Feeder

Hopper conveyor JE series | 5-15L

Hopper conveyor JE series | Drive Control AC 220V

Jäger-Engineering GmbH

Automated insertion into injection molding machine

Automatisiertes Einlegen in Spritzgussmaschine

Spritzguss

Injection molding

注塑成型

injection-molding

In this video, we demonstrate the use of an automated system for inserting components into an injection molding machine. This innovative solution optimizes the production process and significantly increases efficiency.

The operation of the insertion process is shown step by step, demonstrating the precise positioning and handling of the components. The seamless integration of the insertion system into the existing injection molding machine will then be demonstrated, including the communication interfaces and control logic.

The benefits of this solution include increasing production speed and accuracy, reducing scrap and material waste, and improving worker safety by minimizing manual intervention.

An important aspect here is maintaining a low footprint.

Produktion

Manufacturing

Production

製造業

Fabricação

Productie

Produkcja

การผลิต

制造业

Üretim

제조

Produzione

manufacturing

機械人&射出成型機

Robolink & Injection Molding Machine

Robolink & Máquina de moldagem por injeção

Robolink和注塑机

Robolink & spuitgietmachine

Automatisiertes Teilehandling für effiziente Spritzgießautomaten

Robolink e macchina per lo stampaggio ad iniezione

Bestückung

Machine tending

Obsługa maszyn

Mantenimiento de máquinas

機械加工

Machine bedienen

机器操作

기계 관리

機器維護

Équipement

machine-tending

Plastics industry: Automated parts handling for efficient injection molding machines

Whereas employees used to have to place ice scrapers in an injection molding machine hundreds of times per shift, this monotonous task is now performed by a low-cost robot. It is so cost-effective and easy to operate that the investment in automated parts handling pays for itself after just four months.

Monday morning, start of shift at a manufacturer of ice scrapers. An employee places twenty blanks in a magazine and starts the BOY 35 EVV, an injection molding machine that overmolds the scrapers with a lip made of thermoplastic elastomer (TPE). What follows is an example of part handling automation in the plastics industry. robolink, a four-axis robotic arm from Cologne-based plastics specialist igus, grips a blank with a vacuum end effector. The arm then moves to the overmolding machine. The highlight: there are also suction cups on the back of the end effector. This allows the arm to pick up a finished overmolded ice scraper, then turn 180 degrees and place the next blank - with a repeat accuracy of 0.8 millimeters. Removal and loading thus take place in a single motion cycle. And that saves time. The robot arm then places the finished ice scraper on a conveyor belt.

The solution for automated parts handling on an injection molding machine was on display for the first time at Fakuma 2018, the International Trade Fair for Plastics Processing in Friedrichshafen. "The topic of automation is growing strongly in the plastics industry," says Bernd Fischer, division manager for application technology and service at Dr. BOY, a company based in Rhineland-Palatinate, Germany, specializing in the development of injection molding machines since 1968. "Unlike a few years ago, more and more machines are leaving our factory automated today." Before this automation phase, workers had to insert blanks into the machine by hand. Hundreds of times per shift. A monotonous job that is inefficient, tiring and error-prone.

Automated parts handling: payback after approx. four months

Packaging, technical parts, semi-finished products and consumer goods: The plastics processing industry is one of the most important sectors of the German economy. According to the German Plastics Processing Industry Association (Gesamtverband Kunststoffverarbeitende Industrie - GKV), more than 330,000 employees, mainly from small and medium-sized enterprises, generate annual sales of over 65 billion euros. However, this balance sheet is no reason to rest on one's laurels. After all, the sector is going through a transformation phase - just like most other industries. Cost pressure is increasing. And topics such as automation and Industry 4.0 are becoming a competitive factor.

"However, many companies shy away from the topic of automation because they fear investment costs of several hundred thousand euros," says Norman Franke, Head of Automation Injection Molding at igus. "Yet today, thanks to low-cost robotics, it is easily possible to automate monotonous and dangerous processes at low cost and low risk. For example, the robolink robot arm with 5-DOF costs from 3,845 euros - a fraction of the price of conventional industrial robots." The reason for the low cost: Many components of the robotic arm, such as bearings and gears, are not made of metal but of high-performance plastic.

"The investment can pay for itself after just four months," Fischer emphasizes. This is because employees now only have to spend ten percent of their working time on parts handling - namely refilling ice scraper blanks into a magazine from which the robot arm serves itself.

Low-cost robotics is not only comparatively inexpensive to purchase, but also to operate. That starts with operation. "Many companies fear that they will have to spend a lot of money on IT experts to program the robotic arm," says Fischer. "But in fact, after a training period of just a few hours, it's possible even for IT laypeople to define motion sequences." This is made possible by software from Commonplace Robotics, whose origins go back to adult education.

At its heart: a 3D simulation of the robot arm. A Digital Twin of the real robot. Instead of programming, employees define the start and target positions of the arm with mouse clicks. The software calculates the motion paths automatically. It is also possible to insert your own 3D objects. The matching robot controller, integrated in a control cabinet as a DIN rail version, takes care of controlling the stepper motors - and communicates with the controller of the connective injection molding machine via EUROMAP interface. "We have designed the operation of the system so intuitively that the need for IT specialists is reduced to a minimum," emphasizes Fischer. "This saves costs and counteracts the problem of a shortage of skilled workers, which also affects the plastics processing industry."

Since the bearings of the robot arm are made of high-performance plastic and not metal, dry running is possible without lubricants. The lightweight plastic components also reduce energy consumption - another savings factor in times of rising energy costs. Last but not least, the automation does not even require additional space. "The automation of parts handling takes place within the 1.67 square meter footprint of the compact insert molding machine. The company does not have to provide additional space. The low-cost robot, the parts magazine and the conveyor belt are positioned on the free machine table of the injection molding machine to save space."

Low-cost automation of injection molding machines faces a hungry market, Fischer is convinced. He says the solution is particularly suitable for machines with longer cycles. "For cycle times of more than 30 seconds, it makes economic sense for companies to automate part handling with low-cost robotics." For faster machines, on the other hand, robolink is too slow, he said. The robotic arm moves at a maximum speed of 0.25 meters per second and manages seven picks per minute.

Driving automation forward: Online platform RBTX bundles expertise of several manufacturers

If companies like the automated parts handling, they have the option of expanding the automation. This is where RBTX comes in, an online marketplace where manufacturers of low-cost robotics pool their products and expertise. Companies put together automation solutions with the help of a configurator. Robots from igus, for example, provide the basic electro-mechanical framework - including Cartesian robots, jointed-arm robots and delta robots. They can be combined with components from various manufacturers, including vision systems, grippers, interactive software, power electronics, motors, sensors and control systems. Nasty surprises regarding compatibility are ruled out. "To ensure that even small medium-sized companies can make the low-risk leap into the automation age, engineers have already combined and tested all the components," says Franke. "This ensures smooth interaction. Companies can conveniently put together solutions and get started right away."

Handling Etikett

Gluing

접착

涂胶

膠合

Kleben

接着

Lijmen

Klejenie

Collage

gluing

总览

 at the customer's site. This advanced solution is used in combination with a 

 to efficiently label plastic containers.

The igus gantry system provides a flexible and reliable motion platform, while the apiro rotary axis adds rotational capabilities for optimal positioning of the containers during the labeling process. The cab label printer ensures high print quality and speed, leading to increased productivity.

Watch this video to see how this innovative combination of igus technology and cab printing technology revolutionizes the labeling process, ensuring smooth and efficient production.

Logistik

Logistics

Logistiek

物流設備

物流

Logística

물류 시스템

Logistique

Logistyka

搬送装置

logistics

Automated labeling with igus room gantry and a cab label printer

Gluing simulation with a collaborative robot

Customer Tests

Testen door klanten

Tests clients

Müşteri Testleri

客户测试

Tes Pelanggan

Testes de clientes

Testy klienta

การทดสอบของลูกค้า

客戶測試

Kundentests

Test dei clienti

customer-tests

Dispensieren

Dispensing

分发

Distributeur

點膠

ディスペンサー

분배/디스펜서

dispensing

In a customer test in the igus Customer Testing Area (CTA), a gluing process was simulated using a Dobot CRA5 robot. Instead of using a syringe and adhesive, the test involved tracing the contour only. This simulation demonstrates the precise motion control and repeatability of the Dobot CRA5. The robot follows the specified contour exactly, showcasing its potential use in real gluing applications to achieve consistent and accurate results. This type of simulation is particularly useful for testing and optimizing the robot’s capabilities before applying actual adhesive in practical scenarios.

Gluing application with collaborative robot

CTA test 1

A customer test in the igus Customer Testing Area demonstrated that laboratory automation can also be cost-effective. In this test, a pick-and-place task for laboratory applications was performed using the igus ReBel robot and the Schunk EGP25 gripper. The igus ReBel handles precise positioning, while the Schunk EGP25 gripper ensures secure gripping and placing of laboratory samples. This combination enables efficient and cost-effective automation of laboratory processes.

Laboratory

Laboratório

Labor

Laboratorio

Laboratoire

Laboratorium

試験施設

Laboratuvar

实验室

實驗室

연구소

ห้องปฏิบัติการ

laboratory

Laboratory automation with igus cobot ReBeL 6DOF

Automated quality control with igus ReBeL

Automatisierte Qualitätskontrolle mit dem igus ReBeL

Quality Control

Quality control

质量控制

Kontrola jakości

品質管制

Kwaliteitscontrole

品質管理

Control de calidad

품질 관리

Contrôle qualité

quality

In this customer application, a traditional task from the functional and quality inspection domain has been automated using a collaborative robot. Previously, this task required a dedicated worker. Thanks to the deployment of the cobot, this worker can now be assigned to more complex and value-added tasks. The cobot takes over the repetitive and monotonous inspection processes with high precision and reliability. The investment in the cobot was relatively low and paid off completely within a few months, leading to significant cost savings and increased operational efficiency. Additionally, the cobot improves working conditions by relieving employees from tedious tasks, allowing them to develop further and take on more demanding responsibilities.

Automated quality inspection of facets

Automatisierte Qualitätsprüfung von Wasserhähnen

Vision supported Pick and Place application with igus room gantry

Kameraunterstützte Pick and Place Anwendung mit igus Raumportal

Pick & Place

Pick-and-Place

Al ve yerleştir

拾取&放置

픽 앤 플레이스

ピック&プレース

Pick &amp: Place

取放 (揀選 & 放置)

Pick and place

หยิบและวาง

pick-n-place

In this application, a pick-and-place solution was tested for a customer using an igus linear robot, a camera, and a conveyor belt. The individual components had to communicate seamlessly to ensure the metal part could be reliably picked up from the conveyor belt and accurately sorted. The integration of the camera for detecting and positioning the metal part, along with the precise control of the linear robot, played a crucial role in ensuring the system’s high reliability and efficiency.

Jäger-Engineering GmbH

Products from Jäger-Engineering GmbH

Low cost solutions built with RBTX