Full Automation of Injection Molding Line Logistics with AMR Logistics Robots

Watch "Full Automation of Injection Molding Line Logistics with AMR Logistics Robots" on YouTube

Full Automation of Injection Molding Line Logistics with AMR Logistics Robots

Solution Provider: Please log in to view

Application Field: Industry > Construction, Industry > Etc., Application > Logistics, Sector > Logistics

Industry > ConstructionIndustry > Etc.Application > LogisticsSector > Logistics

#marosol#yujinrobot#amr#gocart180#moldinglinelogistics

Process Overview

This case study demonstrates an inline logistics solution that utilizes the Yujin Robot GoCart180 and an upper conveyor module to automatically transport plastic injection products from the injection molding machine to the shipping facility.

By developing a conveyor module tailored to the customer's production line, we automated product loading and unloading, achieving complete automation throughout the entire inline transport process without operator intervention.

Warranty Period

1 Year

Performance Year

2023

Project Duration

Need for consultation

Project Background and Objectives

Injection molding manufacturing in-line labor shortage
Factory operations are disrupted due to difficulties securing workers
Workers avoid work due to the risk of musculoskeletal disorders and industrial accidents

Components

Robot	Two Yujin Robot GoCart180 ; Payload: 180kg ; ISO 13482 PLd safety standard certified ; Operating speed: up to 1.0m/s
Peripherals	Upper electric conveyor module ; Order picking cart ; Middleware

Workflow

STEP 1.	After the injection molding machine injects the food container, it is discharged onto the conveyor
STEP 2.	When the injection product reaches a certain amount, the AMR is automatically called
STEP 3.	The injection product is automatically loaded from the injection molding machine conveyor to the upper conveyor of the AMR
STEP 4.	The AMR moves the injection product to the shipping space
STEP 5.	The injection product is automatically unloaded from the AMR conveyor to the shipping conveyor
STEP 6.	The worker packages and ships the product.

※ 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

Fully automated inline logistics using electric conveyor modules
ISO 13482 PLd certification, safe AMR movement utilizing seven sensors
Preventing industrial accidents through automated transport of high-temperature plastic injection molded parts
Consulting to optimize robot operation based on operational data after solution implementation

Results

Key Benefits	The introduction of robots has reduced the amount of simple transportation work, and the number of simple walking routes for workers during work hours has been reduced by 90%. Robots have replaced these tasks, reducing labor costs by 33%.
Client Feedback	By replacing the 25-meter-long transport task, which required a single worker to walk every five minutes, with AMRs, worker satisfaction has increased and they can now focus on higher-value tasks. By completely separating the hazardous injection molding machine workspace from the worker's workspace, we have eliminated safety risks such as noise and crushing. Furthermore, by establishing the image of a state-of-the-art factory utilizing AMRs during customer visits, we have positively impacted customer orders.

Key Benefits

The introduction of robots has reduced the amount of simple transportation work, and the number of simple walking routes for workers during work hours has been reduced by 90%. Robots have replaced these tasks, reducing labor costs by 33%.

Client Feedback

By replacing the 25-meter-long transport task, which required a single worker to walk every five minutes, with AMRs, worker satisfaction has increased and they can now focus on higher-value tasks. By completely separating the hazardous injection molding machine workspace from the worker's workspace, we have eliminated safety risks such as noise and crushing. Furthermore, by establishing the image of a state-of-the-art factory utilizing AMRs during customer visits, we have positively impacted customer orders.

Recommended Use Cases

Cosmetic Container Packaging through COMAU Racer-5

This automated packaging solution utilizes the COMAU Racer-5 to automate the manual process of loading cosmetic containers into boxes. The system picks up containers arriving in a single line and arranges them into organized rows within the box. It also automates the placement of interlayer sheets (dividers) between each layer of products, ensuring maximum productivity while minimizing management touchpoints. By handling both the product and the packaging material, the robot provides a seamless and efficient end-of-line solution.

Palletizing of 20kg Beverage Boxes using Yaskawa Robots

This heavy-duty palletizing solution utilizes the YASKAWA MH180, a specialized palletizing robot, to automate the stacking of 20kg beverage boxes, handling up to two boxes at once (40kg). By replacing human workers for these high-load tasks, the system prevents musculoskeletal disorders and significantly boosts productivity by handling up to 40kg in a single motion. Furthermore, the robot achieves high transport stability by stacking products in a tightly-packed, staggered (zigzag) pattern, just as a skilled manual laborer would.

Beverage Pallet Unwrapping Solution using Three Hyundai HS220 Robots

This industrial robot solution utilizes three Hyundai HS220 robots to automate the hazardous task of manually removing stretch wrap and straps from beverage pallets. Previously, this process posed a significant risk of safety accidents because workers had to use manual cutters on pallets with high stacking heights. Although the complexity of the task made automation difficult in the past, Hyundai Robotics' specialized solution has made it possible. Additionally, the system neatly manages residual waste, minimizing the need for operator intervention and management.