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Home / Topstar’s injection molding robot calibration fixes ejection position deviation and suction time inconsistency

Topstar’s injection molding robot calibration fixes ejection position deviation and suction time inconsistency

2025/02/28 By Topstar

Injection robot 1-4

In traditional injection molding, problems such as deviation of the ejection position and inconsistency of the suction time of the injection molding robot occur. At the same time, signal delays, poor compatibility, and low stability between devices lead to production delays, equipment failures, and resource waste. Topstar provides a modern and intelligent solution through the open architecture of the underlying control system, which enhances the communication between injection molding machines, peripherals, and injection molding robots. By solving key problems such as signal delays, poor compatibility, and low stability in traditional systems, Topstar’s injection molding robots achieve seamless integration, improving operational efficiency and eliminating common problems in the injection molding process.

Limitations of traditional injection molding robot management

Traditional injection molding systems often have difficulty achieving interoperability between different machines and components, mainly due to the limitations of old equipment management protocols. These systems rely on network protocols to establish connections between injection molding machines, injection molding robots, and peripherals. However, signal delays, poor compatibility, and low system stability can lead to poor communication and inefficiency, especially in high-speed production environments. These systems treat devices as isolated nodes rather than integrated components. The robot may receive delayed commands from the injection molding machine, resulting in premature or delayed part retrieval. Topstar engineers identified this fragmented communication as the cause of ejection deviation and suction failure.

Injection molding robots: integrated operation through system interconnection

Topstar’s solution is to integrate the injection molding robot directly into the injection molding machine control system, overcoming these limitations by adopting an open architecture underlying the control system. This architecture supports local languages ​​for system integration, allowing all connected devices to communicate with each other seamlessly. It enables smooth and efficient collaboration between components. In addition, synchronized operations between the robot, injection molding machine, and auxiliary equipment can be achieved by enabling the injection moulding robot to support host and call signals. In this way, real-time adjustments can be made while also ensuring accurate ejection positions and consistent material intake times. This integrated operation optimizes the demolding process and contributes to more effective and efficient molding operations.

Plastic Molding Machine 80-1

Real-time adjustment improves ejection position accuracy.

Ejection failure is a common problem in injection molding. In traditional injection molding systems, ejection position deviation usually causes this problem. The mold ejection process is inconsistent with the robot’s movement, resulting in product removal failure. This problem can lead to wasted time and material and, in some cases, even a complete stop in production.

Topstar’s injection molding robots can adjust ejection positions quickly to prevent such failures. Their movements are precisely synchronized with the ejection cycle through continuous communication with the injection molding machine and peripheral auxiliary equipment. This ensures that the robot’s arm is always in the correct position, reducing the possibility of ejection failure. Their integration with a broader system enables them to automatically adjust the ejection process based on machine feedback, significantly improving ejection performance consistency and minimizing errors caused by misalignment.

Synchronous linkage between injection molding machine and manipulator

Solve the problem of inconsistent suction time and improve efficiency.

The consistency of suction time is another key factor affecting the efficiency of the injection molding process. Inconsistent suction time can lead to improper mold filling, resulting in defects, reduced product quality, and slower production cycles. Traditionally, operators manually manage suction time, adjusting settings based on their experience or observation, often leading to inaccuracies and inefficiencies.

Topstar injection molding robots solve this problem by automatically optimizing suction time through system integration. Through precise calibration and synchronization with the injection molding machine, the robot ensures that the suction time is consistent and adjusted in real time according to production needs. By relying on automatic adjustments rather than manual intervention, human errors are eliminated, suction is consistently applied for optimal mold filling, production delays are reduced, and the quality of molded products is improved.

Improve Line Efficiency through System Calibration

The core benefit of integrating Topstar injection molding robots into control systems is their ability to improve line efficiency through system calibration. Traditional equipment often requires manual calibration and adjustment, which is time-consuming and error-prone. By implementing a fully integrated system, Topstar’s robots can make real-time dynamic calibration adjustments, eliminating downtime and reducing the need for manual intervention.

This continuous process optimization ensures that engineers perform every operation at maximum efficiency, from injection to ejection and suction. The calibration process occurs seamlessly within the system, allowing precise control of all movements and processes. As a result, there are fewer line interruptions, better resource utilization, and more stable output. This integration not only improves the performance of the injection molding robot but also improves the overall productivity and profitability of the entire manufacturing process.

Ultimately

By leveraging an open architecture system to ensure seamless integration between injection molding robots, injection molding machines, and auxiliary equipment, Topstar has created a more efficient, reliable, and precise manufacturing process. The ability to solve problems such as ejector position deviation and inconsistent material intake time through system integration solves common production problems and optimizes the entire injection molding process.

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