Robot Motion Recalculation for Injection Molding Cycle Optimization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for removing injection-molded items from injection-molding machines using robots are inefficient, leading to high unproductive time due to deceleration requirements, costly hardware, and movement interruptions, which result in increased production cycle times and costs.
Innovation Solution
The method involves applying signals from signaling devices to the open- and closed-loop control units of both the injection-molding machine and the robot, recalculating the robot's motion sequence after each cycle to anticipate and synchronize movements, allowing for earlier start times and reducing delays, thereby optimizing the removal process without additional hardware costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the robot is equipped with massive drives and power transmissions to achieve high speeds, then the speed of the robot is improved, but the device complexity and cost increase significantly
Solution Approach 1:
The robot control unit calculates and stores optimal motion sequences in advance, including pre-acceleration phases before the mold opens and pre-positioning movements. This allows the robot to be ready to receive parts without requiring massive drives, as the timing is optimized beforehand based on mold cycle data.
Solution Approach 2:
The system dynamically adjusts robot motion parameters based on actual mold cycle times and part ejection timing. The control unit continuously optimizes acceleration and deceleration profiles to match the specific production requirements, replacing static high-power drive designs with adaptive control.
2Manufacturing precision
If the robot decelerates early to reach target positions accurately, then the positioning precision is improved, but the productivity decreases due to extended cycle times
Solution Approach 1:
The system performs preliminary calculations of the complete motion sequence including acceleration, deceleration, and positioning phases. By storing optimal motion profiles that anticipate the mold opening time and part ejection moment, the robot can maintain higher speeds throughout the cycle while still achieving precise positioning when needed.
Solution Approach 2:
The robot motion is continuously optimized to eliminate unnecessary stopping and starting. The control unit ensures the robot is in the optimal position and state throughout the entire mold cycle, maintaining continuous productive action rather than intermittent movement with multiple deceleration/acceleration cycles.
3Adaptability or versatility
If separate control units are used for the injection-molding machine and robot, then the system adaptability is improved, but the coordination efficiency decreases leading to unproductive time
Solution Approach 1:
The control units of the injection-molding machine and robot are functionally merged through data exchange. The robot control unit receives mold cycle data (opening time, ejection timing, cycle duration) from the injection-molding machine controller, and both systems coordinate their actions based on this shared information to eliminate unproductive waiting time.
Solution Approach 2:
The system implements feedback loops where the robot control unit continuously monitors the mold cycle progress and adjusts its motion sequence accordingly. Based on feedback about actual cycle times and ejection timing, the robot optimizes its acceleration and positioning to perfectly synchronize with part availability, eliminating coordination delays.
Data Source
AI summary
Method for removing injection-molded items from an injection-molding machine via a robot and device for performing method. The injection-molding machine and the robot each having a separate drive, and each drive is acted on by a separate open- and closed-loop control unit that is separately programmable. At least the open- and closed-loop control unit of the robot contains a computing element, and the injection-molding machine is equipped with at least one signaling device for detecting a position of the mold. The method includes applying a signal of the signaling device to the open- and closed-loop control unit of the robot, recalculating a motion sequence of the robot based of the open- and closed-loop control unit after each removal cycle, and for each next removal cycle, moving the robot from a start position by a timer at a recalculated start time.