Fully Automated Automation Cell for Injection Molded Parts

Development of a fully automated automation cell for injection molded parts

A manufactured product should be produced in a closed production cycle, without human intervention. The finished system should also be able to produce in flexible operating modes.

Challenge and Objective

Until now, the production of the desired finished product was divided into two work steps on two machines. An employee first had to remove the finished carrier product and then insert it into the next production machine for molding the finished product.

A fully automated automation cell that produces as variably as possible should make this process more efficient. The product flow and the different cycle times of the two injection molding machines had to be flexibly integrated and coordinated via the robot control system. Signal communication between the participants of the automation cell should be managed via a master PLC. Overall, the combined system should become more variable, process-reliable, and faster. At the same time, there should be options for various upgrades, modifications, and different operating modes. A customer’s wish was that the system could be operated independently after completion. This means that simple reprogramming of the PLC, extensions, or maintenance should be carried out by the customer’s personnel.

The challenge was the prototype nature of the system. Its implementation was new territory for the customer. The in-house automation technology was understaffed. Furthermore, the customer had no experience in programming safety-related PLC functions and shutdowns. In addition, the manufacturer of the individual injection molding machines saw no possibility of changing the necessary interfaces.

Solution

Several individual machines were to be combined into a single overall machine. For this purpose, SPIE ESCAD Austria, together with an external partner company, carried out a risk assessment to identify hazards and eliminate them through technical measures. The existing safety devices were recorded to have a locking concept for the future, additional safety door. On site, it was also determined that two safety light barriers are necessary to monitor reaching through a machine into the robot’s area.

With the start of Basic Engineering, the individual interfaces of the two injection molding machines and automation, and the Profinet interface of the robot were analyzed to define the corresponding number of total signals and the scope of the control components. After clarifying the individual interfaces, the planning of the e-documentation (EPLAN and other documents) began. At the same time, the team started with the first version of an operating/user manual based on the requirements specification. Both initial versions (EPLAN and operating manual or functional description) were discussed with the customer. Further customer requests regarding operation and designs were incorporated into the operating manual. The cables to the individual interfaces of the individual machines should be designed as pluggable. This allows the customer to relocate the system to a cleanroom at a later date, without having to disconnect and pull out all cables. The laying of the individual cables and the assembly of the control cabinet were organized according to the customer’s wishes.

After the circuit diagram was approved, the control cabinet could be ordered from a partner company. The same applied to the programming, after approval of the operating manual / functional description. After delivery of the control cabinet, the electronic assembly and commissioning took place. This was completed quickly and included minor optimizations. Since the customer wanted to take over the robot programming themselves, but it was not yet completed at that time, an appointment for optimization was agreed upon two months later.

In the last step, CE certification took place. For this, a few documents for the individual machines still had to be requested. These were summarized and included in the operating/user manual. After completion of the CE marking, the system was accepted by the customer and the project was concluded.

The biggest hurdle during the project was the signal exchange with the individual machines and the self-built automation (packaging of finished parts). Especially the integration of emergency stop signals from the individual machines and the return of the emergency stop signal. Also challenging was the placement of the required control cabinet and the cable routing, as we were not allowed to attach/mount anything to the injection molding machines.

Another hurdle was the definition and implementation of the operating modes so that the individual machines would operate cleanly. Further optimizations were made during commissioning. Additionally, the customer wanted the industrial robot, which they provided and programmed, to take over the control of the system (commands to the individual machines) instead of the master PLC.

Benefits

The customer can now produce the desired finished product in a single production cycle, without human intervention or affecting production. The customer was able to increase their production volume and reduce the duration of the production cycle. Furthermore, the overall system can be operated flexibly with various operating modes.

These strengths of our partner company SPIE ESCAD Austria were utilized

Dynamic and eager-to-learn team that works close to the market
Extensive experience in Basic Engineering and in the automation of complete systems
Flexibility to respond to all problems and challenges
Solution-oriented approach and determination
Complete Development Service from a Single Source
Simple company structure for uncomplicated project execution

About our customer
Our customer in Austria is an international leader in the processing of liquid silicones using the injection molding process.

Industry
Injection Molding Technology

I am very satisfied with the project implementation, as we were once again able to satisfy the customer with the execution. Now our customer can produce in a continuous cycle and increase their efficiency. This project is a good example of how customized automation solutions support a company’s future viability.

Michael Mair
Project Manager Control Technology
SPIE ESCAD Austria GmbH

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