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How to solve the problem of excessive vibration of injection molding robot?

2025/04/09 By Topstar

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Injection molding robots can achieve efficient operation, high-precision grasping, and other tasks in injection molding. Suppose your injection molding robot is not installed firmly, or the overall design is imperfect during molding. In that case, excessive vibration will occur, resulting in inaccurate grasping, affecting product quality, shortening machine life, and ultimately affecting overall productivity. This guide will list the common causes of vibration in injection molding robots and explain how to solve them on Topstar’s robots to avoid excessive vibration and improve operating performance.

Ensure the stable installation and hardware integrity of injection molding robot.

First, let’s start with installation. The main reason for the excessive vibration of injection molding robots may be unstable installation. During the installation process, all mounting devices must be thoroughly fixed, and screws and bolts must be tightened according to the specifications provided by the manufacturer. Any loose connection or insufficient tightening will aggravate vibration and cause misalignment during high-speed operation. At the same time, it is also necessary to ensure the correct alignment of the robot with the injection molding machine. If there is misalignment, it will also increase mechanical stress and cause uneven loads, thereby aggravating vibration. Meticulous attention to detail is required during the installation stage. Stable installation involves choosing a suitable foundation and regularly checking for any looseness – especially in high-vibration environments. Operators must periodically check fasteners and mounting hardware for signs of wear or looseness. By ensuring the injection molding robot is securely fixed.

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Vibration Suppression Technology

Topstar’s Euro series injection molding robots are ideal for high-precision take-out molding. A standout feature of these models is the integrated vibration suppression function, designed for operations that require precise removal. This advanced technology actively monitors and adjusts the robot’s real-time trajectory and movement to counteract any unexpected vibrations.

The vibration suppression function combines sensor data and dynamic control algorithms. These systems continuously analyze mechanical vibrations during operation and adjust the injection molding robot’s movement path instantly. The result is a smoother, more consistent performance with minimized vibration, critical to maintaining high product quality. Field tests have shown that the European series can reduce the vibration amplitude of the end effector by 60-75% when retrieving small precision parts compared to traditional robots. It also works seamlessly with various end effector tool configurations and automatically adapts to different payload weights.

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Leveraging Lightweight A6061 Material

To improve overall performance and reduce excessive vibration, the entire main arm of these machines is made of lightweight, high-strength A6061 material. First, the lightweight of the A6061 material minimizes stress on mechanical components during rapid acceleration and deceleration, which can be a significant source of vibration. Second, its high strength ensures that the injection molding robot maintains structural integrity and performance stability even under heavy loads. Reducing mechanical stress reduces vibration and enables precise control, especially when performing delicate operations such as high-precision insert molding. In addition, using A6061 material enhances the robot’s overall responsiveness. The lighter main arm can move faster and more accurately, ensuring the automated process is efficient and consistent. Combined with advanced vibration suppression, a rugged, reliable gripping system provides excellent operating performance.

A6061 Material

Optimizing Motion Parameters

Proper injection molding robot motion profile programming can significantly affect the vibration level. Avoid using abrupt acceleration/deceleration settings that produce mechanical shocks, and instead use an S-curve acceleration profile to accelerate and decelerate smoothly. Topstar’s programming software includes a built-in optimization wizard that automatically calculates ideal motion parameters based on payload weight, arms reach, and desired cycle time. Consider slightly increasing non-productive move time for vibration-sensitive applications to allow smoother transitions between positions. Many users have found that reducing maximum speed by 5-10% can minimize vibration amplitude by 30% or more with minimal impact on overall cycle time. Fine-tuning these parameters improves performance during high-speed operation and ensures the life and reliability of mechanical components.

Injection Molding Robot End-of-Arm Tooling Considerations

The tools mounted on the injection molding robot can significantly affect vibration characteristics. Make sure the gripper and other end effectors are correctly balanced. Unbalanced tools can generate centrifugal forces that cause vibration, especially when rotating at high speeds. Topstar offers dynamically balanced accessory options with adjustable counterweights for perfect mass distribution. When using suction cup arrays, symmetrically distribute vacuum lines to prevent uneven force distribution. Topstar uses large-bore cylinders for heavy tools to increase thrust and load by 20%, making it easy to handle large parts.

Solving Excessive Vibration with a Comprehensive Solution

Solving vibration in injection molding robots requires a comprehensive approach that combines proper installation, advanced vibration suppression, and high-strength A6061 materials. Manufacturers can significantly reduce unwanted vibrations and improve overall performance during the injection molding process. With the onboard proprietary control system, fine-tuning some operating parameters can further promote a robust and reliable injection molding process.

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