Pipe Insert & Injection Automation with a KUKA KR10

Industry > Metal·PlasticsApplication > Injection·EjectionSector > Manufacturing

#InsertMolding#InjectionMoldingAutomation#KUKA#MachineTending#RobotOnlyControl#24x7Production#PrecisionHandling

This application automates insert and injection handling using a KUKA KR10. It inserts 8 mm × 35 mm pipe parts into a 4-cavity mold. The system is designed with robot-only control (no separate PLC), including the alignment fixture and runner-cutting unit, so trained operators can manage the system through robot operation training.

Project Background and Objectives

Automate insertion of 8 mm × 35 mm pipe parts into a 4-cavity mold
Simplify system control with a robot-only architecture (no PLC) so operators can manage it through robot training

Components

Robot	UKA KR10 6-axis industrial robot Payload: 10 kg Reach: 1,101 mm Weight: 55 kg Repeatability: ±0.03 mm IP54
Peripherals	EOAT (product gripper) Alignment device Supply unit Runner-cutting unit

Workflow

STEP 1.	Supply inserts from the feeder
STEP 2.	Grip the part with the robot (4 cycles)
STEP 3.	Unload the part from the mold and insert the pipe into the mold
STEP 4.	Place the ejected part onto the runner-removal unit for runner removal and discharge

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Features

Robot-only control architecture
Achieves approximately 0.1 mm repeatability for insert placement
Accurate production counting
Stable infeed/outfeed enables 24/7 operation with minimal on-site staffing

Results

ROI Period	1 year
Key Benefits	Stable throughput through continuous operation Clear cycle time enables accurate production planning Resolves staffing challenges due to material characteristics Keeps the existing line running with minimal on-site labor
Client Feedback	The line previously required one dedicated operator per line at all times, but automation now allows one operator to cover two lines, and additional technical training enabled in-house handling of extra tasks.

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