The most popular robot based automation helps the

2022-07-27
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Robot based automation helps the plastic industry achieve efficiency and energy conservation editor's note: green thinking is a simplified idea, which is at least unanimously agreed by the government, business circles and consumers. Concern about the environment is no longer a minor concern of a few people. The industry (including the plastic industry) has paid attention to this situation. Reducing the impact on the environment often leads to lower costs, especially in improving the energy conservation of major environmental factors. Efficiency and energy saving is the most noticeable trend in the industrial and commercial circles at present. In the plastic industry, robots can make the technological process more accurate and efficient, and the robots themselves become more accurate and efficient, which are conducive to enterprises to achieve efficiency and energy conservation

efficiency increase and energy saving are important factors to improve the overall efficiency of the plant. Effective energy management requires the participation of all personnel and departments. At the same time, it also means that enterprises must set goals and clear directions, and energy consumption must be measured for continuous improvement. In order to achieve efficiency and energy saving without the second round of election, the factory must focus on the life cycle cost rather than the front-end cost

cantex has enhanced the mixing screw of three screw extruders by using ABB drives of 75kW, 90kw and 110KW, thus increasing the output by 30%

"most plastic processing plants can reduce energy costs by 10% to 30% through comprehensive measures such as no cost, low cost and investment." Santiagoarchila, manager of plant planning group of husky injection molding systems, Canada, said. This group is specially responsible for the improvement of plant efficiency, and also studies the effective use of machines, which is also an important area with great energy-saving potential. Simplifying feasible plans can reduce the number of machines and save more energy

the injection molding machine factory is studying the whole injection molding process to improve energy efficiency. The correct coordination and use of injection molding machines, molds and peripheral equipment, and the correct selection and installation of process flow will reduce energy and material consumption (such as the number of defective products). Optimizing the process can reduce the downtime, installation, commissioning, heating and startup stages, and shorten the non production time with high energy consumption. Here, not only the maintenance of molds and machines plays an important role, but also automation solutions with good functional performance will have a significant impact

reduce energy consumption per unit product

an important trend in the plastic industry is the shift of injection molding machines from hydraulic transmission to electric transmission. Materialdep n, a Swedish supplier of plastic materials and equipment, conducted a study comparing 160 metric tons of hydraulic and electric injection molding machines operating at the same time each year. With electric drive, the operating cost can be saved by 7000 dollars. Under the same total operation time, the hydraulic drive injection molding machine consumes 16kWh, while the electric drive injection molding machine only consumes 7kwh

another major trend in the production process is to reduce waste, which is exactly the main advantage of using robot units

Toyo, a Japanese injection molding machine manufacturer, claims that users are expected to save 30-70% of energy by using an electric drive injection molding machine. By comparing the 80 ton hydraulic and electric drive injection molding machines with the same operation time each year, it is found that the annual cost savings (including the cost of hydraulic oil and lubricating grease) can be as high as US $4600. The hydraulic injection molding machine consumes 5.65 kwh, while the electric drive injection molding machine only consumes 1.85 kwh. If it is extended to multiple injection molding machines, the economy will be very large

what is related to this conclusion is that people have increased their understanding of the role of motors in the industrial field. For example, cantex is a major manufacturer of polyvinyl chloride (PVC) pipes in the United States. Cantex used ABB's industrial transmission products to upgrade 3 of the 18 extrusion production lines in the factory. The extrusion production line originally used DC drive not produced by ABB. Since ABB drives of 75 kW, 90 kW and 110 kW were used to transform the motors of the mixing screw of the three production lines, the output of the company increased by 30%

abb's machinesync is an energy-saving and time-saving system. Since the robot runs in parallel with the workflow of the injection molding machine, the output of the robot is increased

reduce scrap

another major trend in the production process is to reduce scrap, which is also the main advantage of using robot work units. The international automotive parts company (IAC) is a first-class supplier in the automotive industry. The company has successfully reduced waste products through the use of robots. Before the installation of the latest automatic work unit, its factory in skara, Sweden, shipped products to customers with a defect rate of 150 parts per million. After the installation of robots, this number dropped to 50 parts per million, thus becoming a major advantage in the highly competitive automotive industry. Quality improvement means less waste and less material waste

"as a high-cost country like Sweden, in order to compete in the world market, more enterprises also set their sights on the upcoming Asian aluminum event. We have to try our best to improve efficiency. Robots just improve efficiency, quality and enhance our confidence in products. Robots are essential in our industry." Said stevehammond, iacskara plant manager

in Singapore first engineering company, another example of robot productivity improvement can be found. The company produces ultra-high precision molds and plastic parts for high-tech products such as hard disk drives and PC peripherals. Since the company introduced ABB robots with 6 degrees of freedom in production, the output has increased by 75%, from 170000 to 300000 pieces per month. The quality of parts is improved, the labor cost is reduced, and the company can use energy more effectively

before the robot action, ABB's robotstudio software is used to simulate the actual running action of the robot, which has become an example of lean manufacturing

optimize cycle time

there are other energy-saving methods in the production process. For example, ABB's machinesync is an energy-saving and time-saving system. Because the robot and the injection molding machine work in parallel, the production output of the robot work unit is increased. When plastic parts are taken out of the mold, coordinating the opening and closing time of the injection molding machine can shorten the production cycle and produce more parts. This synchronization also reduces robot wear and helps avoid collisions. It must be pointed out that a typical example involves an irb6650 robot and a 3000 ton injection molding machine to produce a typical automobile part. When the synchronous early advance early closure function is adopted, the part extraction time can be saved by 10%. If it is extended to a machine that operates continuously for many years, the time saved for parts extraction of this machine will reach 10 seconds, and the complete cycle time will be 30 seconds. Therefore, 35000 more parts can be produced every year

load reduction

another major trend affecting the plastic industry is that the automotive industry is striving to produce vehicles with lighter weight and less energy consumption. This has brought great challenges to the automotive industry and its parts suppliers, who need to shift from steel and aluminum based materials to lighter magnesium and plastic composites

people are exploring new technologies to combine composite materials with glass fiber, cloth and metal to obtain materials with rigidity, impact strength and aging resistance similar to metal. In order to produce such parts, it is required to use fibers, metals and embedded textiles for processing, and it is also required to have controllable means to move plastic parts between several processes, which involve stamping machines, molding machines and secondary molding

since the parts must be accurately positioned in the whole process, only a robot with 6 degrees of freedom can meet these requirements. Therefore, the 6-DOF robot plays a key role in the field of developing compact and environment-friendly products

new products and methods help customers exceed their goals and reduce their impact on the environment

lean manufacturing

laser, water jet or mechanical cutting is used to clean, deburr and drill model, thermoformed or foam parts. These cutting technologies are often used to trim automotive interior and exterior parts, such as the carving process of carpets, bumpers and airbags, as well as white goods and large parts, such as chairs and barrels. It still needs a lot of repeated tests to do these jobs well, which wastes energy and discards a large number of plastic parts. By simulating the process flow, all similar problems can be avoided

before the robot starts running, simulating the robot action is an example of lean manufacturing. ABB's robotstudio software allows application engineers to compile the robot's action program in the computer virtual three-dimensional world, and make minor modifications to all steps, and then directly transmit the information to the robot. Therefore, repeated tests are not required to avoid waste and save materials and energy

the Swedish company abbkabeldon has installed an assembly line to manufacture fuse switch isolation devices of different specifications. AVT specma, a complete system supplier, uses robotstudio software to simulate complex process, which not only saves a lot of energy and materials, but also saves a lot of time for the complete system company and users. Before loading the program into the robot controller, all tests are carried out in the virtual environment

saving raw materials

plastic parts of various shapes and sizes are completed in the painting workshop. Therefore, it is required that the temperature of the host should be modified as a whole. Therefore, there must be the potential to save energy and reduce waste. Painting is a difficult process, but ABB has rich experience in this field. Using robots can optimize the whole painting process and reduce the amount of paint. ABB has developed the air recirculation system and the most advanced energy-saving process used in the paint shop, which fully meet the environmental requirements. This solution combines air recirculation, solvent treatment and energy conservation to reduce the consumption of fresh air to one tenth, thus reducing energy consumption. Compared with manual painting, the automatic system can save up to 30% of the paint

the new non-static atomizer robobel021-mini can reduce the paint consumption by 30%. The utility model has the advantages of small volume and light weight, and is suitable for spraying small plastic parts by a small spray painting robot. The new painting process doubles the flow of each atomizer, so the number of paint atomizers and painting robots can be reduced by half. As a result, the floor area of the painting workshop can be reduced by 50% and the time required for the painting process can be reduced by half, which can save energy, reduce paint consumption and carbon dioxide emissions. These new products and methods help customers exceed their goals while reducing the adverse impact on the environment

involving every process

any aspect of the production process, whether it is injection molding, blow molding, extrusion molding or the application of downstream processes such as cutting and painting, robot automation can play their role in improving energy efficiency. Therefore, whether it is to optimize the cycle, save raw materials, reduce waste and substandard products, or produce lighter products, each process step of producing plastic products can save energy, which can be called a real green idea

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