TECHNOLOGY | ROBOTS AND AUTOMATION


example, a packaging unit (rack) through all process modules and ensures high precision in the modules as well as 100% cavity traceability. The parts are not put into the final packaging until all process steps have been completed. This allows the concept to be easily adapted to different packaging variants and requirements. Waldorf says the modular approach has enabled it not only to significantly rationalise project development but also reduce the effort for the qualification and commissioning of the systems. At Sepro, one of the biggest suppliers of


Above: Modular automation system by Waldorf Technik based on Vario TIP platform


standardised automation solutions, Campetella has benefited even more from this growth,” says Market- ing Manager Gaia Campetella. “Large companies have been struggling to find and keep operators to perform repetitive tasks, such as packaging finished products. Campetella provided them with a com- plete range of standard robots to be integrated within downstream automation solutions.” Campetella has turned to 3D printing technology


to produce hundreds of components overnight in a much cleaner and faster process than traditional CNC production. “Moreover, such parts are much lighter than metal equivalents, enabling robots to work faster and without vibrations,” Campetella says. “Wherever possible, our engineers are also replacing pneumatic actuators with electric servo- motors in order to reduce CO2


emissions while


increasing reliability and efficiency.” Waldorf Technik is specialised in the high- speed automation of injection moulding processes in the field of medical technology. It has developed a new modular automation system that it says helps manufacturers of diagnostic consumables such as pipette tips to significantly reduce time to market. “With the global pandemic we all learned that time is even more crucial than before,” says Martin Maier, Head of Sales. “Thanks to the introduction of standardised designs based on the modular automation system, Waldorf Technik was not only able to significantly reduce the entire project development but also reduce the effort for the qualification and commissioning of the systems.” The system is composed of modules for each individual step, such as removal, filter assembly, visual inspection, as well as exchange or refill modules and various packaging modules. Depending on customer requirements, Wal-


dorf’s Vario TIP FSS (Floor Space Saving) module for cavity-sorted filling of a workpiece carrier can be used. This carrier is used to transport, for


54 INJECTION WORLD | April 2022


robotics for injection moulding, Raul Scheller, Managing Director, North America, says: “It is probably not surprising, but medical is the obvious market where we have seen a significant increase in the past 18 months. Fortunately we also have seen increases across the board in almost every market. Due to the continued strong demand from consumers, as well as the labour shortages, our customers continue to move and add automation in their sites. Robots and automation give them an opportunity to further optimise and increase output, and to have full control over their opera- tion. Also, we are seeing customers purchasing robots and/or automation for the first time, many of whom would never have considered it a few years back. They have made this decision in order to stay competitive, and they have seen a good return on their investment. Plus, it provides them with full control of their operation.” The value of robots in a complex injection moulding job is illustrated by automotive supplier KE Elektronik (part of connector company Amphe- nol) headquartered in Kressberg-Marktlustenau, Germany, which produces engine fan connectors by overmoulding four metal contacts with three different plastics. Production is complex and involves numerous testing stages as well as complete traceability. With demand continuing to increase and skilled workers hard to find, the company needed a new intelligent automation solution. It chose EGS Automation to create an automat- ed manufacturing island interlinking two punching and bending units and two Arburg injection mould- ing machines with an output of several million connectors per year, running at cycle times of under 10 s. The result, which fits into a space 15 x 6 m, includes six Motoman robots by Yaskawa, a lot of handling and testing technology, and a palletis- ing system. The plant has been running in three shifts since September 2021. The complete line is divided into four modules. In the first, two punch-bend units ensure continu- ous provision of signal and power pins. Each unit


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IMAGE: WALDORF TECHNIK


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