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How can we improve the safety of the injection robot during operation?

2025/03/14 By Topstar

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In injection molding operations that require high speed and high precision, these injection robots are prone to torque overloads – that is, the torque applied during operation exceeds the preset value. This situation can cause a series of safety issues, including potential damage to the mold, ejector pins, and even the final product itself. The risks are multiplied when injection robot encounter torque values ​​that exceed their safe operating thresholds. Excessive torque can pressure the machine’s key components, causing premature wear or even catastrophic failure. This risk is not limited to mechanical damage but can also compromise production quality, increase downtime, and increase safety hazards for equipment and personnel.

Impact of Torque Overload of Injection Robot on Injection Molding Operations

Various adverse effects may occur when injection robots encounter torque values ​​that exceed the set limits. First, excessive torque puts pressure on the mold, causing it to deform or even crack. The mold is one of the most expensive parts in the injection molding process, and mold damage can lead to costly repairs or replacements, not to mention production delays. In addition, excessive torque can also affect the ejector pins in the injection molding machine. Ejector pin damage hinders the demolding process and causes inaccurate final product dimensions, affecting the overall quality.

Furthermore, when torque overload occurs, it often indicates that the system is operating under conditions not anticipated during the design phase. These unexpected loads can come from material inconsistencies, operating temperature changes, or external disturbances. These factors can cause the injection molding robot to apply forces beyond its safe capabilities. Without proper protection, this situation can lead to a cascade of failures that compromise the structural integrity of the injection molding machine and the injection robot and increase the risk of injury to operators close to the faulty equipment.

Mitigating the risk of torque overload on injection robot through joint soft floating

When the injection robot faces torque values exceeding a set threshold, joint soft floating is designed to provide a controlled adaptive response, preventing excessive stress from transmitting to sensitive components. Joint soft floating allows a limited degree of movement or “float” when subjected to forces that exceed normal operating levels. This floating mechanism acts as a buffer, absorbing and redistributing excess energy from torque overload. In effect, when the injection molding robot encounters an unexpected increase in torque, the soft floating joint deforms slightly, allowing the system to withstand the excessive force temporarily. This controlled deformation helps mitigate the impact on the mold, ejector, and other critical components of the injection molding machine.

Their design combines multiple layers and damping elements to absorb shocks and reduce peak force transmission. As a result, injection robots benefit from significantly increasing their tolerance to torque overloads without compromising the structural integrity of their components.

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Benefits of soft floating joint protection for mold and ejector safety

When a torque overload occurs on an injection robot, the risk of mold damage is one of the main issues, as they are subject to tremendous stress during molding. Even slight deformations or cracks in the mold can lead to low production efficiency, increased scrap rates, and reduced product quality. With soft floating joints, injection molding robots absorb and mitigate the effects of torque peaks, preventing forces from being directly transmitted to the mold.

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Similarly, ejectors are also susceptible to damage when torque overloads occur, whether bending, breaking, or wearing, which can disrupt molding and cause product defects. By adopting soft floating joints, injection robots can better cope with unexpected loads, minimizing the risk of ejector damage. Reducing mechanical stress maintains the ejector’s functionality and ensures consistent product quality over long-term production processes.

Improve production efficiency and equipment stability through advanced protection.

When the injection robot operates within the safe torque limit, it significantly reduces the risk of unexpected downtime or failure. This means the production line can run continuously without frequent interruptions due to equipment failure or emergency maintenance. The increase in uptime directly affects production throughput, allowing manufacturers to meet higher order volumes and reduce total cycle time. Maintaining stable, uninterrupted operations is invaluable in an industry where efficiency is a key competitive factor. The use of joint soft floating protects key components and plays a vital role in stabilizing the performance of injection molding robots over the long term. By mitigating the effects of torque overload, the joint helps maintain consistent force distribution in the mechanical system of the injection robot. This consistency reduces the accumulated stress on components such as molds and ejectors, extending their service life.

Optional personnel protection configuration to reduce accidental injuries

The safe operation of injection robots not only prevents mechanical failures but also protects operators and maintenance personnel. To better solve this problem, Topstar’s injection molding robots have optional personnel protection configurations that greatly reduce the risk of accidental injuries during operation.

Accidental contact with a moving injection robot can cause serious injuries, especially when the machine runs at high speeds and immense torque loads. Recognizing this risk, our engineering team developed and integrated a comprehensive safety suite into the design of the injection molding robot. This optional configuration includes safety interlocks, emergency stop systems, and protective barriers to prevent personnel from accidentally contacting moving parts. The intelligent sensor system continuously monitors the injection robot’s surroundings. These sensors detect the presence of human operators in restricted areas and automatically trigger safety protocols when they identify potential hazards.

Optional personnel protection configuration to reduce accidental injuries

Improved operational safety

The joints’ soft floating technology effectively buffers excessive torque, thereby protecting the mold and ejector pins from excessive stress. This protection mechanism’s benefits are not limited to maintaining the integrity of the equipment; it also helps maintain stable product quality and reduce unplanned downtime. The optional personnel protection configuration further improves the safety of the working environment.

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