| The prime aim of the automation of vertical | | | | The modular robots of the E Series afford the |
| injection machine systems is not to save high | | | | plastics processor a great many advantages |
| labour costs but to ensure high process and | | | | which, when added together, mean "more output |
| product quality, says Engel. Nowadays, handling | | | | for less money": higher speeds and acceleration |
| devices and robots are "run-of-the-mill" equipment | | | | rates with standard versions, various selectable |
| in the manufacturing industry. | | | | levels of performance for digital drive systems, |
| In an vertical injection machine shop, for example, | | | | extended maintenance intervals and greater ease |
| the manual placing and removal of inserts is the | | | | of servicing (through permanent lubrication of the |
| exception rather than the rule, and the same | | | | rack-and-pinion drives, the use of low-maintenance |
| goes for the feeding of moulded parts to | | | | linear guides, the use of plug-in limit switches etc.), |
| downstream finishing stations.The prime aim of | | | | digital monitoring of the vacuum system for the |
| automation is not, however, to save "high labour | | | | suction grippers (with display and control |
| costs" but, rather, to ensure high process and | | | | elements), increased number of optional additional |
| product quality, this being an absolute prerequisite | | | | modules, and, last but not least, availability at an |
| in a modern production facility. | | | | even lower price than that of the previous series |
| Handling devices and robots operate in an exactly | | | | (approx.10 to 15% depending on the actual |
| reproducible rhythm, and at extremely high | | | | equipment fitted). |
| speeds and round the clock.Besides vertical | | | | Robot control systems - intelligent automation |
| injection machine machines, Engel also offers | | | | The user-beneficial integration of machine and |
| matching automation systems - from the simple | | | | robot control systems has been one of the main |
| handling device to the complex production cell | | | | objectives of Engel Automatisierungstechnik |
| incorporating product-specific downstream finishing | | | | GmbH ever since it was founded.Engel's "intelligent" |
| stations.Since all system units are produced by | | | | robotic systems have been constantly developed |
| Engel, the responsibility for everything, including CE | | | | and improved. |
| conformity, rests entirely with Engel.Engel | | | | The many improvements achieved in recent |
| automation, whether standard or special, partial or | | | | years include: the faster synchronization of robot |
| complete, permits reproducibility to the highest | | | | and machine movements - without any additional |
| standard. | | | | hardware - through the use of internal bus |
| Continuous growth from the very beginning Engel | | | | connections between the respective control |
| has been involved in automation technology since | | | | systems, new features for easier operation and |
| the 70s (at that time it was still the parent | | | | programming using menu and teach-in modes, |
| company Engel Maschinenbau), beginning with | | | | extended integrated safety functions. |
| simple pneumatic devices for assisting the | | | | Since the launching of Engel's stand-alone robot |
| demoulding operation.By the middle of the 80s, | | | | control system at K 98, the sale of robots for |
| Engel was already developing servo-actuated | | | | other makes of vertical injection machine machine |
| handling devices and was soon to lead the way in | | | | has increased considerably.Like the "integrated |
| this particular field.By channelling its automation | | | | version" (joint operation of the machine and robot |
| activities into Engel Automatisierungstechnik | | | | control systems via the machine's VDU), the |
| GmbH, which was founded in Steyr in 1985, Engel | | | | stand-alone control system is equipped with a |
| simply surged forward technologically.The Steyr | | | | high-capacity RISC processor and communicates |
| production facility commenced operations at the | | | | with the digital drive system and the sensors and |
| beginning of 1986, with only 20 employees, and | | | | actuators of the robot via a CAN bus.From "high |
| grew continuously over the following ten years. | | | | speed" to "low price" Depending on the application, |
| With a production volume of barely 500 units per | | | | the ERC Series robots are capable of minimizing |
| year, the company was soon "bursting at the | | | | demoulding times to 0.7 seconds and the total |
| seams" and the building of a new production | | | | cycle time to around 4 seconds.For standard |
| facility at nearby Dietach began in 1996.This new | | | | applications, such speeds are really exceptional, |
| facility, with 7,500 my production space combined | | | | but when it comes to using machines for special, |
| with the very latest in process-oriented logistics, | | | | fast-cycling applications (e.g thin-wall packaging |
| as well as 2,500 my office space, commenced | | | | containers), even these speeds are too slow.For |
| production at the end of 1997.After the first | | | | such high-speed applications, Engel has developed |
| year, its 120 employees had already built as many | | | | special ERS Type high-speed robots which have |
| as 650 robots and handling devices.Only two | | | | already proved themselves in actual practice |
| years later, in the business year 2000/2001, the | | | | many times over. |
| company's work force of 210 employees realized | | | | This high-speed version permits robot movement |
| a total production volume of 1000 robots and | | | | speeds of up to 8m/s and an acceleration of up |
| handling devices.This "magic" number was | | | | to 150m/sec2 - that's 15 times faster than |
| achieved two years sooner than originally planned, | | | | acceleration due to gravity! However, fast speeds |
| for Engel had set itself a period of five years for | | | | and acceleration rates alone do not suffice to |
| this growth target.Indeed, annual growth rates | | | | achieve extremely fast cycling times.Just as |
| averaging 25 percent testify to the widespread | | | | important is the optimum co-ordination of the |
| preference for Engel robotic systems. | | | | vertical injection machine machine, the injection |
| For Engel, automation is an essential element of | | | | mould and the robot.The process of "tuning" these |
| modern vertical injection machine machine | | | | three system components even involves |
| production.Indeed, it is becoming an increasingly | | | | optimizing the software running times for the |
| indispensable means of meeting customer | | | | individual program sequences.This facility is a |
| requirements.The robot production facility at | | | | performance feature which distinguishes Engel |
| Dietach has all the necessary means for | | | | systems from those of its competitors. |
| experimental set-ups and feasibility tests, robot | | | | ERS high-speed demoulding robots operate so |
| acceptance tests, with or without machines and | | | | fast that it is possible to achieve a total cycle |
| or moulds, acceptance tests for complex | | | | time of only 2 sec and demoulding times of less |
| automation systems with vertical injection | | | | than 0.3 sec (the shortest demoulding time |
| machine machines (up to 3,000kN clamping force) | | | | achieved so far is 0.235 sec!).Not every application |
| and moulds under actual production conditions, and | | | | calls for a high-end robotic system. |
| prototype production. | | | | For demoulding injection moulded parts and |
| However, in consequence of such rapid and | | | | depositing them on a conveyor belt, the handling |
| extremely positive development, the originally | | | | devices of the ER-HLi Series represent a |
| planned reserves of production and office space | | | | low-cost, integrated means of automation, |
| are now virtually exhausted, meaning that | | | | especially in conjunction with Engel tiebarless |
| extensions to this relatively young production | | | | machines with clamping forces ranging from 200 |
| facility are already in the decision | | | | to 6,000kN.This compact demoulding robot can be |
| pipeline.Fortunately, there is still ample room for | | | | optionally mounted on the moving platen or on |
| expansion at the Dietach site.In parallel with the | | | | the stationary platen.The parts are deposited on |
| company's developments and activities in Austria, | | | | the machine's own integrated conveyor belt |
| robot production for the North American market | | | | behind the safety guard, whereby the area |
| was already transferred in 1995 to a newly | | | | around the mould remains readily accessible, as |
| acquired production facility located in immediate | | | | the conveyor belt can be pushed aside whenever |
| proximity to Engel's vertical injection machine | | | | necessary.The compact design of the system not |
| machine factory at Guelph, Ontario/Canada. | | | | only permits short robot movements and hence |
| Last year, with a work force of 55 employees | | | | short cycle times but also minimizes the required |
| working on a floor area of 4000m2, this new | | | | floor space for the production machine.The |
| facility manufactured as many as 250 handling | | | | integration of the robot control into the machine's |
| devices and robots.While the basic design work | | | | control system makes for optimum ease and |
| for all robotic systems is handled by the Austrian | | | | reliability of operation. |
| company, all customer-specific adaptations and | | | | From the robot to the tray server "Never lose |
| options are realized on the spot by the Canadian | | | | the orientation of a part" is one of the |
| facility.Together, the production facilities in Canada | | | | fundamental principles of automation |
| and Austria plan to manufacture a total of 1,500 | | | | technology.Consequently, many production facilities |
| handling devices and robots in the present | | | | make use of special transport containers and |
| business year. Engel robots - the ultimate in | | | | systems.Widespread use is made of |
| modularity Today, every handling system, | | | | thermoformed plastic trays, especially for parts |
| whether it is a single-axis sprue removal device or | | | | such as mobile telephone housings and |
| a complex ERC (Engel Robot Controlled) parts | | | | components.The injection moulded parts are |
| removal system, is modularized down to the | | | | deposited, temporarily stored and then |
| smallest detail, permitting rapid and flexible | | | | transported in these trays for further finishing and |
| adaptation to individual automation requirements. | | | | assembly (e.g fitting of electronic components).For |
| Theoretically, the available modules can be | | | | this special logistics application, Engel has extended |
| combined to produce as many as ten million | | | | its product range to include, among other things, |
| individual system variants.The modular system on | | | | the so-called tray server. |
| which Engel robots are based has been developed | | | | Moreover, the tray server takes up a minimum |
| consistently and is now in its fifth generation, the | | | | of floor space and, thanks to its integration into |
| so-called E Series.The smallest E Series robot - | | | | the production machine (both into the actual |
| designed for machines with clamping forces | | | | machine and into its control system), affords |
| ranging from 400 to 6,000kN - made its d?but at | | | | optimum ease and reliability of operation.Robots |
| K 98.The medium-sized version (2,500 to | | | | and gripper components on-line Delivery at |
| 18,000kN) has meanwhile gone into production as | | | | extremely short notice is becoming an increasingly |
| well.The largest member of the E Series family of | | | | important factor in the automation field. |
| robots, designed for vertical injection machine | | | | With a view to shortening delivery times, Engel is |
| machines with clamping forces ranging from | | | | currently planning an Internet Ordering vertical |
| 13,000 to 55,000kN, will be presented at K | | | | injection machine System which will ensure the |
| 2001.The E Series thus covers the entire range of | | | | fastest possible delivery of robots and gripper |
| vertical injection machine machine capacities | | | | components to customers in any part of the |
| currently available on the market. | | | | world. |