Two-Pipe Injection Automation with a KUKA KR10

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

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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

ROI Period	1 year
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.