Two-Pipe Injection Automation with a KUKA KR10

Watch "Two-Pipe Injection Automation with a KUKA KR10" on YouTube

Two-Pipe Injection Automation with a KUKA KR10

Solution Provider: Please log in to view

Application Field: Industry > Metal·Plastics, Application > Injection·Ejection, Sector > Manufacturing

Industry > Metal·PlasticsApplication > Injection·EjectionSector > Manufacturing

#MachineTending#KUKA#VisionGuidedAutomation#PrecisionHandling#24x7Production#ProcessStability#IndustrialSafety

This application automates injection handling using a KUKA KR10. It is an automation project that feeds and unloads two types of pipe products into/from a process line. The job requires placement to a specific position with repeatability within 0.1 mm. The system uses a vision-based alignment station for supply handling and improves process stability through precision operations.

Project Background and Objectives

Automate feeding and unloading for two pipe product types
Achieve high-precision placement (≤0.1 mm repeatability requirement)
Stabilize the process using a camera-based alignment fixture and precision handling

Components

Robot	KUKA 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 Camera system Supply unit and related equipment

Workflow

STEP 1.	Feed products from the supply unit
STEP 2.	Align the position using the camera
STEP 3.	Place products on the alignment fixture (2 pcs × 2 cycles)
STEP 4.	Pick four products simultaneously with the robot and load them into the mold

※ The content provided by Bigwave Robotics is protected under U.S. and Canadian copyright and intellectual property laws. Unauthorized reproduction, distribution, or use of this content is strictly prohibited.

Features

Secures repeatability within 0.01 mm
Stable cycle time (CT)
Reliable product infeed/outfeed enables 24/7 operation with minimal staffing
Enables accurate production counting

Results

Key Benefits	Stable throughput through continuous operation Clear cycle time enables accurate production planning Accurate per-tray quantity loading secures downstream buffer time Operator satisfaction increases by reducing frequent safety incidents during process handling Keeps the existing line running with minimal on-site labor
Client Feedback	The process required operators to be constantly assigned for infeed/outfeed, and frequent injuries occurred during manual loading/unloading. Since the infeed material is a metal product with sharp edges, operators complained of finger and wrist pain and were reluctant to work the station. After deployment, 24/7 operation became possible and stable output was secured, improving both productivity and worker satisfaction by replacing hazardous manual handling.

Key Benefits

Stable throughput through continuous operation Clear cycle time enables accurate production planning Accurate per-tray quantity loading secures downstream buffer time Operator satisfaction increases by reducing frequent safety incidents during process handling Keeps the existing line running with minimal on-site labor

Client Feedback

The process required operators to be constantly assigned for infeed/outfeed, and frequent injuries occurred during manual loading/unloading. Since the infeed material is a metal product with sharp edges, operators complained of finger and wrist pain and were reluctant to work the station. After deployment, 24/7 operation became possible and stable output was secured, improving both productivity and worker satisfaction by replacing hazardous manual handling.

Recommended Use Cases

YASKAWA Industrial Robot Hanger-Box Palletizing Automation

Process Overview This deployment uses a YASKAWA GP180 to palletize boxes of hanger products weighing over 20 kg onto pallets. By replacing manual handling in heavy-payload work, it helps prevent musculoskeletal disorders and enables faster, more consistent palletizing performance. Note: Cost may vary depending on the installation environment, robot brand, and payload requirements.

Nut-Insert Injection Molding and Inspection using a Yushin Take-Out Robot

Process Overview This assembly automation solution uses a YUSHIN take-out robot (SCⅡ 150) to perform insert molding, placing a nut into the mold and overmolding it with plastic, followed by automated inspection. By automating both the insert-loading operation and the downstream inspection process, the system minimizes quality-control touchpoints while improving overall productivity.

Gear Tooth Profile Inspection Using DENSO + QRS Vision

Process Overview This solution is an automated sorting system that combines QRS 2D/3D vision inspection with a DENSO VS robot to pick randomly placed gears, inspect gear tooth geometry, and separate OK parts from NG parts. With QRS's in-house vision technology, the system can be tuned and customized to match specific site conditions, enabling precise inspection across various gear shapes and models. This project was implemented to automate the inspection process after bin picking.