The robot moves synchronously with the ejector of the injection molding machine and takes the cable duct from the machine’s tool. The robot then takes the cable duct to the mounting station, where with high repeatability it presses from three to five clips into the form-fit snap connection in the plastic component. To ensure that this procedure goes smoothly, the clips are positioned ready for the robot. The robot holds the cable ducts in a number of different positions when attaching the clips. The cable duct may not be bent, or it will not be possible to attach the clip. The development engineers were faced with special requirements in which so-called film hinges had to be pre-bent for two types of cable duct. This pre-bending procedure, which obviates the need for cable straps, prevents the lid of the cable duct from breaking.

The robot controller communicates with the injection molding machine via an interface and synchronizes the processes in this way. The conveyor that transports the completed cable ducts away from the cell also receives information about the feed rate and runtime from the robot controller.

• Two KUKA KR 15 robots
• Two PC-based robot controllers, including control panel with familiar Windows human/machine interface
• A separate program for each type of cable duct; the required program can be called up easily by the operator
• A separate gripper for each robot and article
• Two clip mounting stations
• Two vibrators with connected clip positioning unit
• Two conveyor belts
• Interfaces
• Safeguards
• Robot programming
  
  

Supplied by the KUKA systems partner DAT Automatisierungstechnik GmbH, Pappenheim, Germany.

• More consistent quality
  
  By using robots Riesselmann now also enjoys more consistent quality. As far as the defect quota, measured in “parts per million”, is concerned, the company is well on the way to hitting zero. This is a decisive advantage, because a defect on the part of Riesselmann would entail significant costs, both for the company itself and for its customer.
  
  
  
• High process reliability
  
  

  Using a set of sensors, the controller checks whether the feeding station is holding a clip ready for the robot, and whether the clip has been mounted by the KR 15. This results in 100% checking and thus high process reliability.
  
  
  

• Rapid payback
  
  Since commissioning, the robotic cells have demonstrated high availability. Riesselmann thus expects that they will have paid for themselves in about one year.
  
  
  

• Lower manufacturing costs
  
  Reduced personnel costs due to automation have enabled the user to achieve sustainable reductions in manufacturing costs.
  
  
  

• Short cycle times
  
  The KR 15s provide short cycle times, thanks to their remarkable acceleration capacity.