Bushing Mold Insert & Part Removal Automation with a Yaskawa GP25

#InjectionMoldingAutomation#InsertMolding#Yaskawa#GP25#MachineTending#PrecisionInsertion#InProcessVerification#PartStacking

This application automates injection handling using a Yaskawa GP25. It inserts 15 mm bushings into an 8-cavity mold with 0.1 mm tolerance, unloads the finished parts, and stacks them. Bushings are supplied from a feeder, aligned and staged on an alignment fixture via a 2-axis transfer unit, and then gripped and loaded by the robot. After ejection, the robot removes the molded product, verifies insertion, and stacks parts on a turntable stacking unit.

Project Background and Objectives

Automate 15 mm bushing insertion into an 8-cavity mold with 0.1 mm tolerance
Automate product unloading and stacking after molding using aligned bushing supply and precision handling

Components

Robot	Yaskawa GP25 6-axis articulated robot Payload: 25 kg Reach: 1,730 mm Weight: 250 kg Repeatability: ±0.06 mm
Peripherals	EOAT (product gripper) Alignment device 2-axis transfer unit Supply unit Stacking unit

Workflow

STEP 1.	Supply from the feeder
STEP 2.	Transfer bushings via the 2-axis unit and place onto the alignment fixture
STEP 3.	Grip the staged bushings
STEP 4.	Unload the molded product and verify, then perform insert verification
STEP 5.	Stack on the turntable stacking unit

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Key Features

Secures repeatability within 0.1 mm for insertion handling
Configured with multiple tool types within the gripper/hand for flexible handling
Rapidly processes infeed verification and outfeed verification
Supports stacking configurations matched to the shipping method and required quantities

Implementation Results

ROI Period	2 years
Key Metrics	Product and bushing insert verification during take-out using in-gripper functionality Fast stacking for cases where parts are inserted directly into shipping trays Prevents safety incidents in high-temperature mold operations
Client Feedback	Safety incidents caused by high heat during part removal and bushing insertion were resolved, reducing operator stress and improving morale. Handling small parts had previously caused finger pinching and stress, and the automation reduced both. Shipping-case insertion and stacking time was significantly reduced.