High reliability robots support “traditional technology” plastic moulding operation

Citation

(2006), "High reliability robots support “traditional technology” plastic moulding operation", Industrial Robot, Vol. 33 No. 3. https://doi.org/10.1108/ir.2006.04933caf.001

High reliability robots support “traditional technology” plastic moulding operation

High reliability robots support “traditional technology” plastic moulding operation

Keywords: Plastics, Robotics

For most manufacturing businesses, deciding to link the latest in robot technology with traditional moulding processes would be a challenging undertaking. But for market leading manufacturer and supplier of circuit protection, cable management and wiring devices, MK Electric, this decision has helped them to deliver a consistently high-quality product and simplified manufacturing processes. The use of robots has given this traditional process a new lease of life and has been fundamental to continued manufacture in the UK.

In 1999 MK decided to install its first automated moulding systems, using FANUC Robots, to help simplify the manufacturing process while improving quality and process repeatability (Plate 1). Dave Trechsler, MK Manufacturing Engineer, explains, “When compared to injection moulding technology, compression moulding is sometimes branded as 'old fashioned', however, the process gives us the aesthetically high quality finish that is essential for this product.

Plate 1 MK have been using FANUC Robots since 1999

“Equally important, are the insulation properties, heat resistance and scratch resistance of thermoset material that further enhance the product's qualities. The down side to the compression process compared to injection moulding was the need to manually unload and handle mouldings with care while ensuring they were allowed to cool evenly and consistently.”

MK now has three FANUC M-710i robots unloading mouldings from eight presses – two robots serving a five-press cell and one robot serving a three-press cell. Each robot unloads mouldings from the press and moves them through a variety of processes including de-flashing and cooling before the component is finally packed for assembly.

“The robots run 24/7 over 365 days of the year and have done so now for over five years – a combined operating period in excess of 100,000 hours,” Dave explains, “'the FANUC robots' reliability has been excellent with the only replacements required being three new motors.

“Overall the use of robots has improved health and safety by reducing cuts and burns from manual handling; it has improved the quality/integrity of the mouldings through consistency of handling and has improved the overall efficiency of the process.”

Improvements to the manufacturing process at MK are continuous and plans to introduce further developments are in the pipeline together with the rollout of an additional FANUC Robot cell.

Further information: Maurice Hanley, National Sales and Marketing Manager, FANUC Robotics (UK) Limited, Tel: 024 7663 9669; e-mail: sales.fruk@fanucrobotics.co.uk; www.fanucrobotics.co.uk