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Industrial Robots

KraussMaffei industrial robots are fast, versatile and rugged. They are used to automate sophisticated demoulding, trimming and assembly processes. The great flexibility of their 6-axis kinematics makes them ideal for tasks too complex for linear robots. KraussMaffei supplies intelligent solutions based on standard robots, including making good use of dead time to extract maximum value for the process.

Concept

We have the know-how to make articulated-arm robots work for your application and we use this expertise to develop the most effective solution for your production. Key is the awareness that the choice of robot is determined less by the payload and more by the reach. With two robot types (Kuka and Motoman), the KraussMaffei’s IR series cover the whole spectrum of injection moulding machines.

We offer four installation options for integrating industrial robots to do a specific production task – and the solution will be a perfect partnership between machine and robot.

Optimal for big machines: our shelf mounted (S type) industrial robots are mounted on a console usually installed on the fixed platen of the injection moulding machine. This solution is used especially with big machines over 600 t or for large volume parts. The standard place for depositing parts is the non-operator side of the injection moulding machine.
Optimal for tight spaces: the wall-mounted (W) version is ideal when space is a major constraint on your production, or when a laminar flow box is installed above the injection moulding machine. This solution has another important benefit: the typical movement patterns – swinging in from the side – has the effect of cutting cycle times.
Optimal for integrating peripherals: a floor-mounted (F) version is the classic installation type and still has major advantages. Most important is the very large spherical working range achieved with this type of mounting. It simplifies the integration of additional peripherals, making it possible to fully exploit the flexibility of an industrial robot. Floor-mounted robots also prove highly successful in cleanroom applications where a laminar flow box is mounted above the injection moulding machine.
Optimal for complex demoulding tasks: the integrated (I) version is the preferred choice in applications where space constraints are combined with a complex demoulding process. With the integrated version, these two challenges are met by extending the safety housing of the IMM and by mechanically integrating the IR. The solution also lends itself to cleanroom applications, which can be implemented simply and cost-effectively. Another benefit is the minimal time required to set up the system is up and running in your production – because KraussMaffei precommissions it at our factory.

Technology

Mechanical operation:

Industrial robots are designed to operate over long periods in challenging industrial environments, for example, welding vehicle bodywork. When used for plastics processing, they come nowhere near their load limits, and therefore exhibit exceptionally low failure rates and highest availability over long-term usage. Highly dynamic servo motors, precision gearing and an intelligent controller ensure repeatable high precision. With encapsulated mechanical and electrical systems, IR robots are almost maintenance free, even in dirty environments, and have long service lives.
Industrial robots exert the strength and/or sensitivity required for a specific part – whether it’s large and heavy or delicate and filigree. Even fully extended, the arm retains its enormous stiffness and its ability to manipulate the part at high speed. Programmable sensitivity and precision mean that IR robots deliver higher and more consistent product quality. With their reach, payload and kinematics – six axes moving freely in space – industrial robots can perform the most diverse tasks. Even highly complex demoulding sequences can be handled using only the simplest of grippers. Changes to the production sequence or a switch to different technologies are no problem, as long as the limits of the robot’s reach and payload are not exceeded. Industrial robots are ideal for technical cleanrooms. The cleanroom area can be kept small – IR robots can operate in very tight spaces – keeping investment and operating costs down.

Power and signal supply to the grippers:

Activating and controlling gripper activities – demoulding, inserting and assembly – requires electrical inputs and outputs, monitoring functions and pneumatic valves. KraussMaffei employs two different concepts to supply these functions:

Arm-mounted unit:

An arm-mounted unit is available to provide a centralized supply for the valves and signals of the grippers or peripheral equipment. Because it is mounted on the third axis, the unit can be used for any size robot. The unit is supplied via a field bus cable and pneumatic line.

Gripper interface module:

On large robots, a gripper interface module mounted between arm and gripper can provide the same functions as the arm-mounted unit. The chief difference between this module and the arm-mounted unit is the smaller, integrated cabling package and the fact that this solution avoids the robot’s singularity. With its integrated demoulding stroke and wider reach this unit extends the capabilities of the industrial robot.

Operation and control

There’s a misconception that operating industrial robots must be complex and difficult. Not with our intelligent operating and control concept! Operators control the system directly via the robot operator panel or the operator panel of the injection moulding machine. Operators don’t need to use the handheld pendant and are therefore never confronted with robot programming. The person responsible for setting up the system uses a handheld with a simplified, always identical KraussMaffei Automation user interface. This interface provides all the functions he needs to change the product, optimize the program and perform diagnostics. Only the system programmer has to deal with the complex manufacturer’s user interface.
There are two control concepts – a basic and a high-end concept. Which one is chosen depends on the complexity of the application. With the basic concept, simple peripheral equipment can be easily integrated. The components are the operator panel, the handheld with KraussMaffei Automation user interface and manufacturer interface. If several robots or different robots and complex peripheral equipment are to be integrated, then the high-end concept, which is a superset of the basic concept components, is the better choice for higher level control. The advantages of this space-saving control concept are, among others, robot independent control, the uniform user interface, and an easily expandable, technology-dependent user interface.

Customer benefits:

  • You work with just one contact partner for the whole complex manufacturing cell; we handle all the project planning details.
  • You get a system that is easy to operate, despite performing complex processes. Only your programmers need special training. Setup staff and operators need only simply instructions.
  • The robot functions Start, Stop, Automatic operation, Manual operation and Return to home position can also be integrated in the operater panel of your injection moulding machine This allows the robot and machine to be programmed simultaneously or separately.
  • Push-button return to home position reduces collision risk after a stoppage.
  • Programmable safety systems are easy to expand.
  • CE conformity: all systems are planned in conformity with current safety standards.
  • Using standardized components reduces system cost and your capital investment.
  • Shorter cycle times and faster amortization of your investment through integrating pre- and post-mould processes.
   LRX/LRX-S series
Linear Robots
 
IR series industrial robots (1.4 Mb)

   KraussMaffei - People for Plastics  

KraussMaffei is one of the biggest names in plastics processing technology, designing, manufacturing and supplying leading edge injection and extrusion equipment.

Committed to continuous improvements and with a solutions-based approach, we work closely with our customers and supply chains to deliver productivity improvements, technological breakthroughs and market-leading innovations.

 






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