Constantly posting best times KraussMaffei Automation Engineering Passion
2 KraussMaffei Automation Facts and figures KraussMaffei Automation We control all clamping forces Series Clamping force Robot type SPX LRX LRX Twin IR-F IR-S 35 50 PX 160 400 CX 500 550 650 850 GX 900 2,500 MX 4,000
3 Constantly posting best times KraussMaffei Automation Automation is becoming ever more important as a decisive success factor in production. Today, a high degree of reproducibility when inserting components, demolding finished components and linking successive production processes by way of automation are essential elements in reducing production costs and ensuring a high standard of quality. Acting as a systems partner, KraussMaffei Automation will work out the optimum solution for your production together with you. Basis of the product portfolio: linear robots (LRX) or industrial robots (IR) series and the SPX sprue picker Combination of different series as a network Implementation of complex production cells Extensive technological know-how
4 Customized solutions KraussMaffei Automation With KraussMaffei Automation Straight to the goal Product solutions Customer Linear and industrial robots and sprue pickers are standard products and important tools for turnkey solutions. Customer requirements define the degree of automation. Control solutions Customer Machine panel controls automation Automation Machine Automation panel controls machine MC6 look and feel, fault-free programming and straightforward operation with reciprocal control.
5 Customer Competence solutions Development and installation of standard robots, design of turnkey solutions, programming and commissioning and worldwide 1st level service and direct 2nd level support. Customer Technology solutions Insertion. Demolding. Inspection. Packaging. For all technology solutions. FiberForm is just one of many possible examples.
6 Customized solutions KraussMaffei control concepts Different automation solutions for your production KraussMaffei control concepts Standalone concept KraussMaffei robots with MC6 user interface Concept for self-sufficient automation Retrofitting for older KraussMaffei or non-km machines Same mechanical configuration Use with different injection molding machines in production Full range of functions of MC6 interface Available for LRX and IR series Versions: LRX-S and IR-S Integrated concept KraussMaffei robots with MC6 user interface Two control points for injection molding machine and automation Injection molding machine can be controlled from the robot handheld pendant Simple "switching" between injection molding machine and automation in the software Shared data retention Simple program change Central control point Convenient operation and controls on large systems Versions: LRX and IR High end concept PLC interface in MC6 design for greater usability Link between several robots and peripheral equipment in a single cell (mixed system) Use for many parallel processes Shared mode management Central control point (HMI) Central data transmission, e.g. to printer, BDE and traceability system Central fault and diagnosis management Service-friendly troubleshooting Machine panel controls automation Automation Machine Automation panel controls machine
7 Pick and place Introduction to automation Automation requirements Simple demolding with robot Deposit on conveyor Expandable at any time High degree of modularity Turnkey solutions High end technology applications Implementation of customer-specific requirements Inserting, demolding, turning over, machining, testing and packaging No boundaries CE-compliant production cell with MX 800-8100 injection molding machine, LRX 350 linear robot, conveyor and protective housing Turnkey system for manufacturing a cover for a kitchen machine using three-component technology Your benefits: The requirements determine the degree of automation from simple to complex Custom solutions Flexible modules Expandable concepts
Fast. Precise. Economical. SPX10 sprue picker The servo sprue picker from KraussMaffei features a very compact and stable design. The telescoping stroke makes the SPX10 particularly well suited for use in low shop heights. It forms a unit together with the machine, providing the optimal solution on the market for use in small spaces. 30 percent less height The telescoping stroke is an inwardguided rail system which ensures that when the system moves into home position, the total mechanical stroke is reduced by half. This means that unlike fixed axes, the entire stroke does not extend upwards. The servomotor enables the sprue picker to operate extremely fast and saves on maintenance time and expensive compressed air compared to wear-prone pneumatic drives. The integration into the MC6 control system and the optimized parking position for mold changing round out the user-friendly features. Quick demolding Thanks to the freely configurable waiting position of the gripper, for example just above the mold, the removal time is significantly reduced. Quick machine cycles can be implemented easily. The detached sprue is stored within the standard machine housing. This means that there is no need for a side extension in the form of a protective enclosure. This way four machines can be installed in the same installation area instead of three. With the optimal gripper module, the SPX10 can demold and deposit even small parts using a vacuum. The telescoping stroke saves more than half a meter of height Optimized standby position permits fast demolding times Your benefits: Compact design within protective housing Telescoping stroke for use in low-ceiling halls Servomotor-controlled axes for free programming Quick demolding time of just 0.75-1.2 s Load capacity >1000 g
9 Everything from a single source perfectly co-ordinated Conceived as a system solution Easy programming The greater the variety of control systems and operating philosophies introduced into a production system, the more complicated operation becomes and the more time is wasted. The SPX10 is fully integrated into the MC6 control system. The operating language and philosophy remain the same. The WizardX ensures maximum ease of programming just press a button and the picker is programmed. One supplier for everything At KraussMaffei, we are systems thinkers. This approach, combined with longtime experience in complex automation solutions, guarantees that you have production cells perfectly tailored to one another. Interface, protective housing, CE conformity or all-in-one control system everything is ready to use and custom-built to your requirements. Integration of SPX 10 in the MC6 interface WizardX, the assistant for fast programming Your benefits: Easy programming with WizardX Only one data record has to be integrated into the MC6 control system One contact for automation and injection molding machine
Flexible for standard processes or special solutions Linear robots in the LRX/LRX-S series Increase the productivity and quality of your production process in injection molding machinery through synchronization with reliable and quick automation. KraussMaffei can provide you with the complete range of injection molding automation solutions from a single source. Universal application The linear robots in the LRX/LRX-S series from KraussMaffei distinguish themselves by their wide range of variants. They cover a clamping force range of 350 kn to 54,000 kn, and can be used universally for all types of injectionmolding machines irrespective of brand or manufacturer. Linear robots are equipped with three linear axes and up to three wrist axes, undertaking the most varied of tasks in the injection molding process. High level of system functionality The LRX/LRX-S series is based on the proven control system concept of KraussMaffei injection molding machines: easy to operate, program and control. Standardized safety technology and periphery components such as belt conveyors and safety housings are matched with the series, thereby ensuring absolute safety. Robots of the LRX/LRX-S series are dynamic, fast and precise: demolding times under a second are possible with repeatability of +/- 0.1 mm. Your benefits: Modular system CE-compliant production cells Cost-effective entry-level solutions Increase the degrees of freedom through numerous wrist axis combinations Flexible gripper solutions Quick demolding times Precise repeatability High level of productivity
11 Smarter programming and operation WizardX programming assistant The perfect symbiosis of machine and automation As a system partner, we supply the automation technology and machine as a fully integrated, overall concept. The machine and handling system form a functional unit in this case. The joint control system allows both functional units to be managed on any control panel: Automation technology and machine. The machine can be operated via the handheld pendant of the robot, and vice versa. No witchcraft: the WizardX programming assistant For linear robots from KraussMaffei, there is an online programming wizard, called "WizardX", which is used in conjunction with the MC6 control unit. It makes programming the robots enchantingly simple. Thanks to intuitive operator guidance with visual representation, the WizardX is an effective aid for programming. Even beginners can create basic demolding processes within a very short space of time. The interactive communication between the user and control system makes manual programming superfluous and eliminates programming errors. WizardX programming assistant 8.5 inch handheld pendant Your benefits: Smarter programming and operation with WizardX Prior programming knowledge is not essential Quick and easy basic programming for pick and place applications Error-free program generation Reduced training expenses
+ Flexible production options Linear robot in versions Twin X and Twin Z The possibilities for combining several axes can be extremely varied. The following case studies show several different application options for multiple kinematics. Configuration Twin X Characteristic Mechanically linked Y-axes on a shared X-axis Application Simultaneous demolding or placement process in the mold Benefits Save time when using a three-plate mold Configuration Twin Z Characteristic Mechanically linked X-axes on a shared Z-axis Application Transfer of components (handshake) during rapid component removal or stacking operations Benefits Space and time saved on automated units with overlapping motion ranges Configuration Control of additional peripheral axes Characteristic Additional axes (peripherals) for the standard robot Application Use of turntables and stages Benefits Central control, can also be used for external axes Flexible configuration of axes Easy identification of the active robot on operating screens Integral collision monitoring
13 Versatile, convenient and easy to operate Multiple kinematics for linear robots Multiple kinematics offer you a host of benefits in the implementation of complex automation solutions. such as the assignment of an associated production process to several robot axes. The MC6 control system manages the process and all moving axes are programmed and controlled centrally using a handheld pendant. What are multiple kinematics? The MC6 control system from Krauss- Maffei was further developed to allow the central programming and control of linear robots with a maximum of 24 axes. The software allows the configuration of up to 4 kinematic units (robots), each with 6 axes. Multiple kinematics are the perfect starting point for the development of complex automation solutions used in production. Extended options A joint program editor is used to program all the robots. Program commands and parameters can be assigned to individual robots with minimum effort. A joint coordinate system for all axes makes it easier to control specific robots in individual operating modes. Multiple kinematics on LRX/LRX-S The integral LRX version offers the added convenience of alternate operation using the panel on the injection molding machine or the handheld pendant on the robot. The standalone version of the LRX-S is a self-sufficient, independent system that incorporates all the usual advantages of the MC6 control system. This version is used in all applications where integration in the injection molding machine is not an option. Your benefits: Implementation based on the MC6 control system Support of four robots, each with 6 axes (max. 24 axes) Central control of movements using the application program Operating mode changed centrally Intelligent collision monitoring of mechanically linked axes
Automation technology Flexible concepts No limits for your requirements Industrial robots of the IR/IR-S series IR stands for industrial robot. They implement complex demolding processes with a wide variety of grippers and freely programmable sequences of movements for wide swiveling ranges. Six axes enable enormous flexibility, even in spots where linear robots cannot be ideally used. KraussMaffei provides you space-optimized production units and mobile cells with the shortest return to service time, according to your requirements. The IR series is the solution for comprehensive, customer-specific automation requirements. Krauss- Maffei creates custom production cells with standard components from pick and place to turnkey solutions. Heavy-duty basic units Industrial robots are designed for extreme ambient conditions and continuous operation for example, when welding body components. When used in plastics processing, they do not brush up against their performance limits, but rather distinguish themselves over a long operation period with the highest level of service. Highly dynamic servo drives and high-precision gear boxes, synchronized with an intelligent control system, provide for continuously high positioning accuracy. The right partner for every purpose According to the specific application or individualized customer request, we choose the robot with the corresponding options for integration into the system. This ensures that the selected robot will be the best fit for the special features of your application. Your benefits: Turnkey automation solutions from a single source Optimal positioning and space-saving installation types for injection molding machines Excellent operating concept Integration of various peripherals Flexible gripper solutions Integration of industrial robots, also for older KraussMaffei systems and machines of other manufacturers
15 For intelligent control and programming Two user interfaces: VisuX and ProgTechX VisuX user interface Industrial robots are highly complex. Our intelligent operating and control concept simplifies programming and operation enormously. The robots are operated either directly via the robot control panel or via the injection molding machine control panel. With the handheld pendant and the simplified VisuX user interface installed on it, the system user has an overview of all the functions that are essential for operating the production cell. Our VisuX user interface with operating functions and process data on just seven functional pages reduces complexity for user-friendly programming. ProgTechX programming support Basic programs can be written quickly using the new ProgTechX programming support. This clever command library with what are known as in-line forms makes the programming process incredibly easy and ensures error-free programming. MC6 visualization on KCP robot Your advantages with VisuX: The same logic as MC6 machines and linear robot control All the necessary robot functions are combined on one interface Fast process adjustment Optimal diagnostics functions When integrated into an injection molding machine, reciprocal control is possible and a common logbook is provided VisuX: coherent control concept with the MC6 look and feel ProgTechX: the simple command library for fault-free programming Your advantages with ProgTechX: Reduced programming times Syntax errors prevented Pre-defined command sets with pre-assigned input options Programming library for operating sequences (e.g. loading, demolding, archiving) is included
16 Automation technology PLC control Robots and peripheral equipment centrally managed KraussMaffei PLC control: the high end Implementing highly complex automation with many control elements and linking them in a straightforward manner is the standard of the KraussMaffei PLC concept. A superordinate control with the MC6 look and feel makes this possible. When do I need a PLC control? The requirement is determined very quickly from the degree of automation and the number of peripheral elements to be integrated. A superordinate, programmable logic controller (PLC) is indispensable if several robots with complex peripheral equipment are to reconciled. The central elements here are the insertion and the demolding robots, robots and peripheral equipment for providing insert parts and downstream robots and peripheral equipment such as a camera system, label (barcode) printer or a labeling laser. MC6 as central system control element With such automation solutions, the PLC control forms the link point between all control systems, but is also assumes the function of a control point. That saves time and travel at the start of the production process. As with all KraussMaffei products, a user interface with the MC6 look & feel has been created to make operating the system easy. The user is immediately at home in the familiar user interface. That reduces the time and cost associated with training, makes it easier to operate the system and creates a solid basis for troubleshooting. Operating concept and extension packages Siemens TIA portal (Totally Integrated Automation) in conjunction with an integrated Win7 Embedded form the basis of the engineering environment. The combination of the two systems (PLC and PC) greatly simplifies the integration of outside systems as well as the control and maintenance of all components. The KraussMaffei PLC concept forms the basis, providing for the quickest possible support by remote service in the event of system downtime. Optionally diagnosis tools for the peripheral stations, emergency strategies (selecting/ deselecting stations and inspections) or customer-specific applications can also be integrated. Your benefits: Quick and simple control of complex automation systems Time savings due to PLC linking of all robots and peripheral equipment Reduced training and maintenance costs Visualization of system layout on the high end control Integrated printer interface
For complex automation solutions Versatile peripherals 17 Precise sorting and feeding units Sorting and feeding units are necessary for insertion technology or subsequent processes. For such processes, the robot requires the components to be in a reproducible, aligned position. A further plus: the peripherals can be integrated directly into the robot control system, so that only one control unit is required. Most varied of grippers Whether simple grippers with standard components such as vacuum exhausters, parallel grippers, sprue gate grippers or complex inserting and demolding grippers, we have the perfect solution for you. Benefit from economical solutions for your special requirements. Depending on the application: the right camera systems and testing systems We have the right solution to suit your requirements. Simple camera systems are used when it comes to measuring, checking and counting components with straightforward shapes. Configurable image processing systems check safety-relevant components and complex geometries, undertake checks that need to be documented and carry out highly accurate measurements at high checking speeds. A great number of the tests run simultaneously, and require a great deal of lighting. Other checking systems, e.g. for pressure checking and short-circuit checking, are available on request and can be integrated into the production cell. Different drawer systems They are used for providing parts, exporting QA components and for buffer storage. In addition to single and double drawers, a combination of drawers and chutes is a further equipment variant. Each drawer system is equipped with a request and acknowledge button, as well as a protection guard. Custom delivery systems We can provide you with standard delivery systems such as belt conveyors, conveyors for different product types, roller conveyors and chain conveyors which are driven by motors or gravity. Depending on what your application is, we can create an optimum concept for you. Pallet cages, pallets, cardboard boxes and small load carriers with different designs (e.g. multi-track) can be conveyed to or from the process. Your benefits: Single-source system solutions Individual modular technology concepts Integrated complex peripherals Fast product change-over
18 Automation technology Gripper solutions for every task Keep all your products under control with gripper solutions For every task and every sector Thanks to many years of experience in system and gripper construction, KraussMaffei has automation expertise that goes well beyond purely standard tasks. Know-how from practice One of the core competencies in the field of automation is gripper construction. The gripper, the heart of the demolding system, must work 100 percent in order to guarantee the availability of a system. Our specialists therefore have many years of experience in conceptional gripper construction. We have the necessary know-how, both as an original equipment manufacturer and in the field of retrofitting existing and new grippers. Gripping carriers from the printer Single-part production at close-to-series production costs is the dream of a mechanical engineering company that offers its customers customized solutions. KraussMaffei is making this dream reality thanks to an innovative production technology: 3D printing. The process of selective laser sintering makes it possible to manufacture highly complex geometries in one-off production. The focus here is on the substitution of subcomponents of the gripper construction. Air and vacuum lines, connection threads or braces can be easily united to form a single component. That saves time in design, production and assembly. In addition, a cost- and space-saving design can be implemented. Example from practice Gripper unit with old, classic concept. Four grippers mounted in the required positions on a metal plate, 1,400 grams in weight. 3D printing makes the cost-optimized implementation of a tailor-made design part, free of superfluous material possible. Weighing in at just 720 grams, the modified gripper is little over half as heavy as its fully metal counterpart. Your benefits: Gripper for inserting, demolding, turning over, positioning Production of customer-specific grippers Construction on the basis of sample parts Design based on 3D parts and tooling data Standardized components for costefficient applications 3D printed applications for maximum flexibility
19 Industrial robot training with the KraussMaffei training cell With our mobile and compact training cell, all necessary industrial robot training sessions can be conveniently held at your plant. Prevent any potential interruption of production and save yourself the cost of travel and accommodation. We come to you. Reality in miniature Our training cell is equipped with a fullfledged industrial robot from KUKA, which offers all the functionalities of an industrial robot in real use. Moreover, the cell includes a model of an injection molding machine that represents the entire interface of a real injection molding machine. Extensive peripheral equipment The compact dimensions of the training cell (only 80 cm wide by 140 cm long) enable it to be set up in almost any conference room. Power is supplied via a 16A shockproof socket. The compressed air for the gripper functions is generated using an integrated, low-noise compressor. The cell also has other peripherals, such as a gripper, a conveyor belt and more. With this cell you can program and simulate all of the standard sequences of an actual production process under real-world conditions. Your benefits: Training at your facility Avoidance of possible loss of production Training cell with a full-fledged industrial robot from KUKA Simulation of the injection molding process based on a model including all interfaces Compact dimensions of training cell: just 80 cm wide and 140 cm long Power supply (shockproof) Save cost of travel and accommodation
20 Automation technology Service We are at your service KraussMaffei Automation service To ensure the long-term availability of your machines and systems, we can offer you a wide range of services customized to suit your needs. 1. TRAINING With qualified personnel you will gain a high level of production, machine and system safety. KraussMaffei offers you an extensive program of training courses which can be held either at our training centers or individually at your location. Details can be found in our current training program. 2. SPARE PARTS SUPPLIES When customers need something, our top priority is to supply the required original spare parts as quickly as possible. The stocking of all standard components and fast and competent support in processing are additional focus issues. Component repairs Do you need repair work done on a part or component? Make use of our parts repair service and entrust us with the task. 3. TECHNICAL SERVICE HOTLINE In case of technical problems or system downtimes, a fast and competent solution is supremely important. With our expertise and dedicated support, we ensure that your system is back to running perfectly as soon as possible. With our extensive worldwide service network with well-trained technicians, we can troubleshoot and resolve your problem quickly. Teleservice Our ultra-modern teleservice gives us direct access to your system. That allows you to benefit from fast fault diagnosis and assistance. In close consultation with you, we establish a modem connection with the control unit of your system and are quickly able to diagnose the current status. 4. PREVENTATIVE SERVICE Precautionary service largely prevents unplanned and costintensive downtimes. Inspections/maintenance Regular service on your system will help to retain the value of the system and safeguards against cost-intensive machine breakdowns. We can offer you various maintenance programs and inspections. We use our specialist tools and measuring equipment to analyze the state of your system and to define and implement the necessary measures early. Using a checklist, we check your system's electrical, mechanical and control system components, as well as its safety devices. The resulting documentation tells us what spare parts or other action is needed.
21 5. FUNCTION ENHANCEMENT Should the range of functions of your system be modified or enhanced for new tasks? We will be pleased to support and advise you. Make use of the experience in our team. First-class support with our remote service Our modern control units give you the option to locate the causes of errors on your automation system quickly and accurately. This is where, in consultation with you, we connect via modem to the relevant control unit on your machine, and this enables us to quickly identify hardware or setting errors online and usually rectify them as well. This can prevent downtimes, and you save time and money. Free software updates can be installed remotely, as can most purchased software packages. This facility saves the time and cost of a service technician. Commissioning new molds Do you need technical application support for programming of new automation sequences, reduced cycle times or optimized automation processes? Again here, our specialists are there to help you. Relocation, modification or expansion We are equally your competent partner if you and your automation systems face major demands such as system relocation or modification of the technical range of functions for new tasks. Spare parts packages Our active service management also covers everything from consulting to the selection of spare and wear parts tailored to your requirements. W will give you detailed advice depending on the particular features of your systems and components. Your benefits: High levels of machine and systems availability due to regular inspections and maintenance for planning security and cost transparency Optimum operation and use of your automation systems due to trained staff Modern service support and optimum spare parts supplies Fast overview and diagnosis of current status of your system using teleservice Support for new demands on your production in different ways You will find our complete range of training courses online at www.kraussmaffei.com
22 Automation technology Further information Further information This might also interest to you You're looking for the right injection molding machine? We have the right system for every production task. We have also compiled extensive information for you on the subject of service. This will help you increase the flexibility of your injection molding machines and robots for ever newer process requirements, and continuously increase their capacity. We would be happy to provide you with detailed information on this. For example, ask us about: Industrial robots in the IR series Versatile tools for productive automation The basis for economical manufacturing SPX10 sprue picker. Fast. Precise. Economical. You can find our brochures and fliers on other topics online at www.kraussmaffei.com. On request, we would also be happy to send you information and technical data for our products free of charge.
23 KraussMaffei A strong brand in a unique global group Cross-technology system and process solutions Whether in Injection Molding, Reaction Process Machinery or Automation the KraussMaffei brand stands for pioneering and cross-technology system and process solutions in plastics processing worldwide. For decades, our expertise, innovative ability and passionate commitment to plastics engineering have been your competitive edge. As a cross-industry system provider, we offer you modular and standardized systems as well as solutions customized to your needs. There for you around the world With our worldwide sales and service network, we offer our international customers an excellent basis for a successful business relationship. Due to the close proximity to our customers, we are able to answer your individual inquiries very quickly. We work out the best possible technical and economical solution for your product and production requirements together with you. Test our machine technology for your applications and let our experts put together an individualized service package for you. Individualized service Our employees from customer service, application technology and service help you with your questions and needs on every topic dealing with machines, systems and processes around the globe, quickly and with a high level of expertise. We have developed an extensive customized service spectrum with our lifecycle design, which accompanies you throughout the entire lifecycle of your machines and systems. Take advantage of the personal interaction and flexibility we offer in our practically oriented seminars. We carry out customer-specific trainings either at your location or at our sales and service locations. KraussMaffei Group Comprehensive expertise You can find additional information about KraussMaffei at: www.kraussmaffei.com Unique selling proposition Technology 3 The KraussMaffei Group is the only provider in the world to possess the essential machine technologies for plastics and rubber processing with its KraussMaffei, KraussMaffei Berstorff and Netstal brands: Injection Molding Machinery, Automation, Reaction Process Machinery and Extrusion Technology. The group is represented internationally with more than 30 subsidiaries and over ten production plants as well as about 570 commercial and service partners. This is what makes us your highly skilled and integrated partner. Use our comprehensive and unique expertise in the industry. You can find additional information at: www.kraussmaffeigroup.com The KraussMaffei Group has a global presence. Countries with subsidiaries are marked in dark blue. In the white-colored regions, the Group is represented by over 570 sales and service partners.
Constantly posting best times KraussMaffei Automation Automation is becoming ever more important as a decisive success factor in production. Today, a high degree of reproducibility when inserting components, demolding finished components and linking successive production processes by way of automation are essential elements in reducing production costs and ensuring a high standard of quality. Acting as a systems partner, KraussMaffei Automation will work out the optimum solution for your production together with you. The basis of the product portfolio are linear robots (LRX series), industrial robots (IR series) and the SPX 10 sprue picker. Combinations of different series as a network (PLC) and the implementation of complex production cells round off the core competencies of our project planning. Benefit from our extensive technological know-how with over thirty years of experience in automation. We are your competent partner for your individual corporate goals. www.kraussmaffei.com/automation 1.0 WE. 3rd edition 10/17. IMM 313 A BR 10/2016 EN Subject to technical changes Printed in the Federal Republic of Germany.