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How do user needs influence the design of injection molding robot?

2024/09/28 By Topstar

Injection molding robot (1)

In the manufacturing industry, the technical application of equipment is closely related to the use of users. For plastic product manufacturers, injection molding robot play a key role in realizing process automation, improving precision, and improving overall efficiency. As a classic product developed and produced by ourselves, the technology of injection molding robots is constantly evolving. From the first generation of servo manipulators to the fifth generation of five-in-one servo manipulators, every detail reflects the deep thinking of our engineers on customer needs.

Injection molding robot precise, energy-saving, intelligent five-in-one servo

For manufacturers, the high cost of each stop and collision during the injection molding process is the most significant driving force for our product development. To meet customers’ needs in more fields, Topstar has implemented an upgrade based on the underlying technical architecture of software and hardware. The development of self-developed control system algorithms and “five-in-one” servo drives realize more precise, energy-saving, and intelligent injection molding robots.

AC-Servo-Injection-Robots-EU-80SII

After our technical development and research, Topstar’s R&D team launched the “five-in-one servo drive,” which enables one servo drive to directly control 5 servo motors directly, making the removal control more precise. The driver uses only three CPU chips to achieve a five-axis-in-one design by allowing each CPU chip to control two axes, and the maximum power of each axis is 750W. This provides mighty power for the injection molding robot. At the same time, the energy efficiency is improved by 20% through the multi-axis standard busbar design.

Multi-track application of the self-developed open system of the injection molding robot

“We want to launch new products, can your robot support the solution?” This is a question asked when communicating with customers. Most customers in the market have unique products, which has led to the demand for customized and multi-track equipment applications such as injection molding machines and injection molding robots. In this regard, Topstar’s self-developed open system can provide great convenience for operators and support the best automation application for exploring new processes. You only need to use the hand controller to modify the program, servo parameters, and mechanical parameters or modify the application program according to your needs to achieve traction, hook, slip, oblique line, and even irregular removal paths. You can also achieve particular actions such as arrangement, stacking, counting, sampling, etc.

Improved Speed ​​and Efficiency

Manufacturers in the market want to increase productivity while minimizing production cycles continuously. Therefore, Topstar uses lightweight aluminum alloy arms on the fifth-generation injection molding robot, which reduces the entire machine by 20 structural components and weight by 20%. The lightweight and high-strength A6061 material in the central arm improves overall operating performance. Our engineers focus on optimizing the robot’s movement speed and acceleration while ensuring that they can handle the fast cycle of the injection molding process. Combining advanced motion control algorithms and lightweight materials can significantly increase the speed of these machines. In addition, features such as parallel processing can further improve efficiency.

Your technology is so mature, what is the technical content?

From the first to the fifth generation of five-in-one servo manipulators, Topstar has obtained more than 60 patents in developing injection molding robots. For example, the “arched driven wheel” and “pick-and-place integrated manipulator” realize the “fast pick-up and light placement” action function of fast descent in the mold to pick up objects and slow descent outside the mold to place objects. The acquisition of patents proves Topstar’s innovation ability in the field of injection molding robots and reflects the depth of manipulator technology. The integration of software and hardware enables robots to grow, and through training in many application scenarios, their scope of application is more comprehensive, and their performance is better.

Mechanical structure
Posture parts

To reduce costs, we also need to upgrade intelligence

“Nowadays, competition is fierce. On the one hand, we want to reduce costs, and on the other hand, we also want to upgrade our production workshops and equipment to intelligence.” This is also the idea that many customers have told us. To this end, Topstar takes the following steps, from equipment intelligence to production line automation and then to upgrade the entire intelligent factory.
The first step is to select a five-in-one servo injection molding robot with system extensibility to ensure the compatibility of intelligent upgrades. At the same time, it makes production operations simpler. The second step is to connect it to the injection molding equipment signal to realize the automation of independent injection molding units and create an automated production line by combining series units.

The third step is that if your company needs workshop information upgrades, you can access the MES system and IOT digital platform through the reserved expansion interface. On the diversified terminals, you can realize real-time monitoring and timely optimization of the extraction automation process to achieve information management. The fourth step is to use the digital platform for data collection, analysis, and decision-making. Using data-based decision-making will significantly reduce management costs and improve decision-making efficiency.

MES system

Let users experience better, smarter, and more efficient products

Users influence the design of injection molding robots’ needs regarding technology and application scope, including accuracy, speed, integration with modern technology, safety, and other factors. As manufacturers in various industries continue to develop, these needs are essential for developing equipment to improve productivity and maintain competitiveness. At Topstar, we are committed to providing injection molding solutions that meet the unique requirements of our customers.

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