VERSATILE TOOLS FOR PRODUCTIVE, COST-EFFECTIVE AUTOMATION. IR series industrial robots

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1 VERSATILE TOOLS FOR PRODUCTIVE, COST-EFFECTIVE AUTOMATION IR series industrial robots

2 IN PARTNERSHIP WITH INDUSTRY KraussMaffei is a premium partner for the plastics and rubber processing industries worldwide Automotive White goods Construction Medical / pharmaceutical Electrical / electronics Whatever you aim to achieve in plastics or rubber processing, KraussMaffei is your partner. We are the only company with intensive expertise across the three main engineering fields. And we have a strong track record in integrating this expertise to develop new processes and systems. Ready for any challenge Our Injection Moulding Technology Division supplies machines and systems for standard and special applications, very large machines and fully automated solutions. Our main markets are in the automotive, packaging, electrical, electronics, medical technology and consumer goods industries. Our Reaction Process Machinery Division supplies machines and complete systems for processing polyurethanes and other reactive materials. Completing our product portfolio, Tooling Technologies supplies foam moulds, cutters and routers. Our customer base is wide, with a focus on the automotive, construction and white appliances industries. Our Extrusion Technology Division supplies machinery and systems for compounding, for pipe, profile and sheet extrusion, physical foaming, and the production of technical rubbers and intermediates for tire production. Machinery from the company s range from single extruders to complete extrusion lines is used in many industries, including chemicals, pharmaceuticals, automotive, construction, furniture and packaging. People for Plastics We are the people for plastics. We are your partners from the first exploratory discussion, through development to commissioning, servicing and operating your system, and final disposal. At all times, you are assured of outstanding competence in planning and engineering, as well as reliable and fast spare parts, service and support. Adding value for customers We put our expertise to work for your success. With machine ranges engineered for modularity, we can deliver application-specific solutions based on our wide range of standard modules and specially engineered solutions. This strategy offers customers technical and cost advantages. Close to customers around the world As an international company, KraussMaffei has a presence in all the major markets for the plastics and rubber processing industries and employs over 3,000 people worldwide. Our sales and service network keeps us close to all our customers around the world.

3 IR industrial robots for cost-effective, application-specific automation systems Packaging IR standard industrial robots are used in complex automation solutions. A KraussMaffei IR robot is your cost-effective route to a highly customized manufacturing cell. Engineered to exploit non-productive time, IR robots enable intelligent solutions that maximize value added in plastics processing. In injection moulding applications, industrial robots are used for complex demoulding and post-mould processes. Six axes mean an enormous jump in flexibility and reach compared with linear robots for interfacing with peripheral processes, for installation options, for versatile gripper use, weight and geometry. KraussMaffei is your system supplier for application-specific manufacturing cells from simple pick&place to complex turnkey solutions based on proven and cost-effective standard components.

4 TRANSPARENT TECHNOLOGY Meet the robot: discover some key benefits of the IR series Flexibility is critical IR robots can be integrated in compact production units and even in mobile units, ready to go soon after relocation. With six servo motors, freely programmable 3D movement sequences and a wide working range, IR robots make it easy to implement complex unloading and post-mould processes using simple grippers. Simple operating concept With three levels programming, set-up and operation our concept helps you to allocate employee resources and skills effectively. Cost-effective turnkey systems Our system concepts are intelligently engineered and field-proven. Expandable Hardware and software are designed for easy integration of peripherals at any time. CE conformity Guarantees safe and reliable operation and reduces your costs. Safety that grows with the system Programmable safety features can be expanded without problems if your system changes. Power supply and signal transmission An arm-mounted unit or a gripper interface module are space saving solutions and easily accessible for fast maintenance. Press-button home-position cycle Simply pressing a button returns the robot to the safe home position. The interfaces are our business As your single-contact partner, we ll supply turnkey systems injection moulding machine and robotics complete and ready to go. Versatile and flexible, IR industrial robots are a future-proof investment Page 4 Transparent technology

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6 Console mounting Wall mounting DESIGN BASICS Choose the installation option that s best for your application KraussMaffei offers four basic options for integrating an IR robot into your production environment. Shelf mounting optimal for large injection moulding machines The shelf-mounted IR version (S) is usually mounted on the fixed platen of the injection moulding machine. This solution is mainly used with large machines (over 600 t clamp force) or in applications where large-volume parts are produced. Shelfmounting can also be the answer when access to the mould is limited, eg, with side-mounted mould changing carriages that are wider than the daylight between the tiebars. Wall mounting optimal for tight spaces The wall-mounted version (W) is the answer when production space is very limited, or when the area below the unloading position can be more productively used for another process. For example, a packing unit could be installed below the unloading station to deliver a reliable and space-saving solution that could be varied to suit your product. Wall mounting has another important benefit: since the IR robot arm can swing to the side, cycle times can be significantly reduced. Page 6 IR series industrial robots

7 Floor mounting Integrated into the injection moulding machine Floor mounting optimal for integrating peripherals The floor-mounted version (F) is the classic version among the various installation alternatives. Its biggest advantage is the robot s large horizontal working radius. This action radius allows complex peripheral stations to be integrated, eg, for assembly or quality control. Floor mounting makes maximum use of the enormous flexibility of an industrial robot. This mounting option can be very effective in cleanroom applications where a laminar flow box is installed above the machine. Integration into the injection moulding machine optimal for complex demoulding Integrated installation (I) is the option of choice when two constraints apply: space is tight and the demoulding process is complex. In this solution, the industrial robot is mechanically integrated and the safety housing of the injection moulding machine is extended. This type of integrated solution makes it possible to implement cleanroom applications simply and cost-effectively. There s also the extra benefit of faster commissioning for your new system, because it will have come successfully through preliminary acceptance tests at the KraussMaffei factory. Mounting options Page 7

8 DETAILED PRODUCT INFORMATION Reach is the deciding factor the right choice makes all the difference KraussMaffei offers you a decisive advantage. As your system partner, we have the resources and knowhow to deliver a complete solution the injection moulding machine, the process engineering and the automation. We ll work with you to deliver the optimal solution for your business. Application-specific system solutions We know exactly how robot elbow kinematics can be used to advantage to deliver the best possible solution for you. When you re choosing a robot, you need to consider that reach is more important than payload. With a track record of hundreds of successful applications, we are specialists in the integration of industrial robots for injection moulding applications. And our after-sales service is second to none. Our knowhow will pay off for your company. Engineered for tough conditions Industrial robots were designed for harsh environments and continuous use for example to weld automotive body parts. In plastics processing, they come nowhere near their performance limits, and therefore exhibit exceptionally low failure rates and highest availability in long-term use. IR 30 F IR 60 F IR 200 F IR 500 F IR F IR 1650 F IR F IR 2000 F IR S IR 1650 S IR S IR S-XL Clamping force in kn 350 KM 35 CX 500 KM 50 CX / EX 650 KM 65 CX 800 KM 80 CX / EX 1100 KM 110 CX 1300 KM 130 CX 1600 KM 160 CX / EX 2000 KM 200 C 2500 KM 250 C 3000 KM 300 C 3500 KM 350 C 4500 KM 420 C 5000 KM 500 C 5750 KM 575 C 6500 KM 650 C MX MX MX MX MX MX MX MX MX MX MX MX Page 8 IR series industrial robots

9 Industrial robots selected and configured for your machine and application 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. Versatile and flexiblee With their reach, payload and kinematics six axes moving freely in space industrial robots can perform the most diverse tasks. Changes to the production sequence 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. Investment and operating costs are often lower, because the cleanroom area can be kept small IR robots can operate in very tight spaces. KraussMaffei experts can integrate existing and/or new robots and peripheral equipment from almost any manufacturer. We specialize in solutions. If six axes are not enough, eg, to service a 5400-tonne injection moulding machine, then we add additional linear axes to take the industrial robot into the machine. Or if space is limited, we ll mount a robot on the ceiling. Return on investment The injection moulding machine sets the cycle times. If the robot can utilize non-productive time within the cycle, the whole system will operate more cost-effectively. Industrial robots with their special kinematics can fill this time with other tasks, such as deflashing, flaming or assembly. Shorter inactive periods and greater productivity result in lower manufacturing costs. The higher initial investment in an IR robot will quickly pay off. Costs can also be saved by making best use of the robot kine-matics and using simple, lower-cost grippers instead of the complex grippers demanded by other solutions. Versatile and flexible, industrial robots can handle any task in injection moulding today and all foreseeable tasks in the future. And they can be easily adapted to automate other processes. Detailed product information Page 9

10 ADDITIONAL PRODUCT INFORMATION Economic and process advantages are built in it s over to you to exploit them The IR series offers many other benefits from the simple operating and control concept to a universal interface and CE conformity. Simple operating and control concept Our intelligent, three-level concept simplifies operation, set-up and programming. And helps you deploy your staff effectively. Operators do not need training in robot programming, because they work only with the operator panel on the robot or on the injection moulding machine. The set-up specialist will use the handheld its simplified, uniform KMA user interface provides all the functions required to change the product, configure a program and perform diagnostics. Only the person responsible for programming the entire system needs specialized training in using the complex manufacturer user interface. Basic concept or high-end concept There are two control concepts basic and high-end. The choice depends on the complexity of the application. The basic concept is capable of integrating simple peripheral equipment. Its components are the operator panel, the handheld with the Krauss- Maffei Automation interface, and the manufacturer interface. If several robots, or different robots, and complex peripheral equipment must be integrated, then the high-end concept is the better choice for higher level control. It is a superset of the basic concept components. The advantages of this spacesaving control concept include its ability to control any type of robot, the uniform user interface, and easy, technology-independent expansion for the user interface. Operator device/ Operator panel/ Handheld with KMA interface Handheld with User interface injection machine keypad manufacturer interface Target group System operator, Set-up personnel System programmer untrained personnel Features Intuitive, guided Uniform user interface Access to all robot operation Faster start-up and manufacturer functions Critical errors not possible changeover Detailed programming High acceptance Less training required of all robot capabilities Benefit Sets the standard Shows key set-up functions Shows all details

11 Greatest convenience for production and maintenance: arm-mounted unit or gripper interface module Power and signal supply to the grippers Controlling demoulding, insertion and assembly grippers requires a power supply, signal inputs and outputs, monitoring functions and pneumatic valves. KraussMaffei offers two different concepts for these functions: Arm-mounted unit An arm-mounted unit provides a centralized supply for the valves and signals for grippers or peripheral equipment. Because it is mounted on the third axis, the unit can be used for all sizes of robots. The unit is supplied via a field bus cable and pneumatic line. Gripper interface module On large robots, a gripper interface module installed between the arm and the gripper can provide the same functions as the arm-mounted unit. The module differs from the arm-mounted unit in that it has a smaller-dimensioned air supply package and in avoiding the singularity of the robot. It extends the capabilities of the industrial robot by integrating the demoulding stroke and giving the robot a wider reach. Return to home position at the touch of a button A press-button control lets the operator trigger a home-position cycle during automated operation. The freedom of movement allowed by the special kinematics of an industrial robot is inherently coupled with increased risk of collision. This risk is also present after automated operation of the system has been shut down, if the robot is manoeuvred manually, which should naturally only be done by trained personnel. The standard programming of KraussMaffei IR industrial robots enables the home position cycle to be triggered by pressing a button on the operator panel. Programmable safety features Programmable and easily expandable safety features give you flexibility to modify or expand your automated manufacturing cells to match future requirements. Standard interface The EPS connector is the standard, universal interface for grippers and peripheral equipment. This connector ensures reliable pneumatic and electrical connections to the components. It is very compact and is available in various configurations. It also saves time and prevents incorrect connections (poke yoke principle). CE conformity Your safety and the safety of your employees are important to us. Customers who purchase complete systems are assured of CE conformity. From the moment an offer is drafted, all systems are planned to comply with applicable safety directives and regulations. Additional product information Page 11

12 Key IR benefits for you: Easy operation of complex functions in your manufacturing cell Only your programmers need special training, set-up staff and operators need only simple instructions Just one contact partner to handle every aspect of your complex manufacturing cell CUSTOMER BENEFITS We bundle process and system know-how to benefit your business KraussMaffei IR industrial robots open up attractive potential for automating your injection moulding processes, above and beyond standard demoulding. Take advantage of what we can offer you and benefit from our experience. system partners: they mean you deal only with your KraussMaffei contact partner and he or she takes care of all the details. Maximize the productivity of new and older machines It s standard to offer IR industrial robots to automate new KraussMaffei injection moulding machines. But with more than 25 years experience in automation for the plastics processing industry, we have the expertise to provide IR automation solutions for older KraussMaffei machines or for machines from other manufacturers. Always the right partner for robotics Our industrial robot portfolio is focused on robots from two leading robot manufacturers (Motoman and Kuka). Depending on your application or your preferences, we ll integrate the robot that has the specific capabilities required for your application. You benefit from the cooperations we maintain with IMM supplier Customer Robot supplier CE Peripheral supplier System solution Integrator Customer KraussMaffei CE System solution KraussMaffei provides you all systems and services for your system solution from a single source Page 12 Customer benefits

13 The machine and the robot make a perfect team. Application spectrum Demoulding From simple part removal to complex demoulding of large, back-injected parts using special grippers. Example: automotive bumpers Insertion Pick-up and insert parts (electrical components, delicate clips, ) Insert pre-processed parts (die-cut parts, ) Insert preheated parts Example: contacts for plug connectors Cutting Sprue removal Deflashing parts Surface preparation Example: bumper flaming Assembly Assemble supplied parts using industrial robots at separate assembly stations Example: clip assembly for A pillars Quality Control Mechanical testing Electrical testing Visual inspection 100% quality control Example: medical ampoules Packing In cartons, trays, blister packs, bags In cleanrooms Count parts per package Example: fittings Encapsulation Overmoulding glass blanks including clips Example: rear windows Cleaning & Priming Apply cleaner and primer to glazing panes in preparation for further processing Example: quarter windows DecoForm Back-injection of fabric for automotive interior trim Insert textile blanks Post-processing with laser and ultrasonic cutting Example: armrests Ask us about these and other applications!

14 PRODUCTS AND APPLICATIONS The IR series delivers the optimal solution for many tasks KraussMaffei IR industrial robots open up attractive potential for automating your injection moulding processes above and beyond standard demoulding. Take advantage of what we can offer you and benefit from our experience. Application example: Inserting airbag nets and assembling clips Customer Weidmann Plastics Technology AG International developer and supplier of components and solutions for the automotive, medical, sensor components and water management industries. One primary focus is on the development and series production of complex plastic components and metal-plastic composite parts. Task Production of assembly-ready side panels; inserting airbag nets and assembling clips Challenge Precise feed and insertion of a non-shaperetaining fabric in a stable, repeatable process Install delicate clips at various positions on the finished part 100% quality control Performing these tasks to perfection ensures high product quality for the entire process. Solution Proven turnkey solution consisting of a KM CL injection moulding machine, a KR 60 L 30 K S shelf-mounted industrial robot, a KR 15 floor-mounted industrial robot, and extensive peripherals The shelf-mounted robot picks up the magazinefed fabric Insert the fabric into the IMM and demould finished parts Pass the part to the assembly station where robots install the supplied clips Weigh the finished part at a weighing station, and check the part with a camera system Destroy rejects Result Assembly-ready, 100% quality-controlled products leave the manufacturing cell Integrating downstream processing steps cuts cycle time and helps to amortize the investment within a short time Page 14 IR series industrial robots

15 Every step executed precisely in an assembly cell for safety-relevant components Designed-in process stability: concept for the cleaning & priming cell Application example: Cleaning and Priming Customer DURA Automotive Body & Glass Systems Key products are door modules, glazing systems, bezels and trim, and complex technical components. Task Clean and prime side windows Preheat the windows and rails, and feed them to the next process stage Challenge Careful handling for fragile glass windows and delicate rails Precise application of cleaner and primer Precise preheating of the parts Performing these tasks to perfection ensures high product quality for the entire process. Solution Proven KraussMaffei automation concept consisting of two IR 200 F industrial robots in a 2-stage processing cell Pick up manually supplied side windows and rails Apply cleaner Dry Apply primer fluid to aid bonding of the overmoulded border Place the parts on a conveyor belt Preheat the parts and feed them for further processing Result High product quality is guaranteed by gentle handling Combining upstream process steps maximizes productivity Products and applications Page 15

16 Flexible space utilization with the IR series Application example: Assembly cell Customer Biro Edwin Bischof AG, Switzerland Develops and moulds technically sophisticated thermoplastic parts. Specialist for multicomponent technologies for different industry sectors: automotive, household, construction and electrical. Task Install clip nuts on automotive interior parts in an standalone cell. Challenge Stable process for precise feed and assembly of 12 clip nuts at different positions on a finished part, plus the ability to adapt quickly and easily to different products. Solution Standardized KraussMaffei clip nut assembly cell with IR 30 F industrial robot Parts produced on a KM 650 CZ multinject machine are demoulded by a demoulding robot and placed in a easily exchangeable, productspecific fixture The clip nuts, which are difficult to automate due to their shape, are supplied from an integrated hopper, and subsequently singled and aligned by an integrated sorting and feed unit The nuts are fed in a row ready for the robot The IR 30 F, the smallest KraussMaffei industrial robot, assembles 12 clip nuts on the part using a technically advanced nut assembly head Result Compact manufacturing cell with shortest startup and restart times Manual production possible if production line is down Competitive edge thanks to very flexible production Page 16 IR series industrial robots

17 Fully automated cleanroom for consistent quality Application example: Cleanroom cell Customer Olho-Technik, a company of the Olho Group Specialist for components meeting high surface quality specifications, and for kinematic elements in automotive interiors. Task Cleanroom production of assembly-ready, printed face panels for radios Challenge Technical cleanroom Precise positioning of inserts supplied precisely oriented and cleaned Solution Proven turnkey solution consisting of a KM C2 injection moulding machine, an IR 500 F industrial robot, and complex peripheral equipment Inserts are supplied in a buffer unit that moves horizontally Insert pick-up, centring, and dust removal in a cleaning station The insert/demould gripper positions cleaned inserts precisely in the mould On completion of the injection moulding process, the industrial robot unloads the finished parts and presents them to a barcode printer After printing, the parts are placed on a conveyor belt Result High product quality due to gentle handling and clean room environment Integrating upstream and downstream processes cuts cycle time for faster amortization of the capital outlay by adding value beyond injection moulding. Products and applications Page 17

18 SERVICE WORLDWIDE Service, support and spare parts when you need them, where you need them Rely on us for a fast and competent response to all your service needs anywhere in the world. Whatever you need from troubleshooting or training to spares or repairs we re on the job. We re dedicated to supplying service quality on a par with the outstanding quality of our machines and systems. We offer far more than spare parts and hotlines. We ll work with you to choose the best and most cost-effective solution for your operation. We ll help you test new applications and we ll plan customized service packages. All-round service Our service offering is broad. We ll configure your system, install and commission it, train your staff, plan measures to minimize your downtime risk and maximize productivity, and carry out maintenance, repairs and upgrades. You ll find us fast, reliable and competent. Our hotline is manned by highlytrained and experienced service technicians. If necessary, we ll get a technician to you quickly. Remote diagnosis, interfacing directly with your machine s control system, can be a practical alternative. Spares for all important wear parts are available at short notice. We re continuously expanding our service network to speed up spare parts shipment. Talk to us about the right service solution for your business. Customer trials and prototyping in our test lab The Injection Moulding Division operates a test lab fitted with the latest machinery and equipment. We can run trials, produce prototype parts and fine-tune processes on your behalf. We can work with you to test and evaluate processes, machines and equipment in order to identify the best approach for a particular project. Our highlyqualified application engineers are there to help you. Training with high hands-on content Courses are held in our lab and training centre, or, optionally, on your premises. We offer clearly-structured basic and advanced training in operation, process control and maintenance for KraussMaffei injection moulding machines. On request, we ll plan and hold special courses on topics of your choice. All participants spend a high proportion of their training working hands-on with original KraussMaffei machines. A well-structured training program produces skilled operators and technicians, which will positively impact your up-time and productivity. Contact for training: Rupert Gruber Phone: + - Fax: + - rupert.gruber kraussmaffei.com

19 At your service worldwide Team Europe Injection Moulding Service Team service-imm.europe kraussmaffei.com Injection Moulding Spare Parts Team spareparts-imm.europe kraussmaffei.com Team America/Spain Injection Moulding Service Team service-imm.america kraussmaffei.com Injection Moulding Spare Parts Team spareparts-imm.america kraussmaffei.com Team Asia/ Near East Injection Moulding Service Team service-imm.asia kraussmaffei.com Injection Moulding Spare Parts Team spareparts-imm.asia kraussmaffei.com How to contact us Apart from you can contact us on the service hotline or by post at this address: Hotline Phone: + - Fax: + - Injection Moulding Service Krauss Maffei GmbH Krauss-Maffei-Str. Munich Germany

20 KraussMaffei is a premium partner for the plastics and rubber processing industries worldwide. KraussMaffei machines and systems are used wherever plastics and rubber are converted into products. As a knowledge-driven technology company, we build on many decades of experience and a strong commitment to research and development. Flexible and versatile, KraussMaffei s IR industrial robots are an efficient, cost-effective route to application-specific automation solutions. We offer a comprehensive product portfolio with the optimal robot for any brand of injection moulding machine and for complete, standalone work cells. The versatile robots, capable of interacting with a great diversity of peripherals, represent a future-proof investment. The intelligent control and operating concept and our standardized components combine to reduce the complex functionality of a manufacturing cell to easily manageable operations. Benefit today from our experience in supplying complete solutions combining machines, process engineering and automation. 1.0 WE 1st edition 12/07 SGM 099 A PRO 12/2007 GB KraussMaffei reserves the right to make technical changes. KraussMaffei Technologies GmbH Krauss-Maffei-Strasse Munich Phone Fax