Cobot UR10 helped to speed up the production and increase effectivity
01 THE SHORT STORY
2D&S s.r.o. is engaged in molding plastics, or more precisely thermoplastics, as well as producing tools for molding these materials. Based in Kuřim, 2D&S offers its customers range of complex services that include, among other things, the design of the product model using construction software. Among other things, the company pays great attention to shortening delivery times while maintaining high quality end products.
- Full automation of the process where plastic IML foils are being loaded into the injection molding machine
- Fast integration of collaborative robot into production process
- Ability to let the robot work independently
- Secure and easy access to the workplace for existing employees
- Minimalization of routine tasks
- Increase of production speed and efficiency
- Low costs of building a workplace
- Flexibility of the solution
- Maximum possible automation of the injection molding process
- Operation of the injection-molding pressing machine with the UR10 cobot
- Loading of IML plastic foils into the pressing machine
- Ensure secure access for existing employees
- Avoid construction costs
Video — 2D&S, Czech Repulbic
02 THE Challenge
"Recently, the greatest challenge for our company has been work efficiency, increased productivity and the shortest possible production cycle," says David Dědek, CEO of 2D&S, s.r.o. Increasing customer demands for speed and product quality led the company to the decision to fully automate the thermoplastic press machine. It was also important to eliminate the cost of any building modifications to the factory that would require the purchase of a standard industrial robot.
03 THE Solution
Based on numerous positive references, it was decided to purchase a collaborative robot UR10 from Universal Robots, which meets the most demanding requirements for reliable integration into the existing manufacturing process.
Primarily, the UR10 cobot is designed to be used to insert IML (in-mold labeling) foils into a plastic mold. With IML technology, a multilayer plastic foil is embedded in plastic during the manufacturing process. When the plastic foil is inserted into the pressing machine, it is melted to the outside of the plastic mold. Partial melting of the IML foil ensures adhesion to the plastic. Plastic foil will thus become an integral part of the final product, such as a returnable plastic cup that can be found at outdoor events or festivals.
The production of plastic cups is a very monotonous activity, but it requires great precision in the handling and loading of plastic foils into the machine. The workstation where the robot is placed must be collaborative because the human worker puts the plastic foil in a tray from which the robot subsequently takes the IML foil. In view of the size, it is also necessary to overcome the relatively large distance from the tray directly into the injection molding machine. For this purpose, the UR10 from Universal Robots with a large working range is the ideal choice.
“The production of plastic cups has dramatically improved. At the beginning, we had minor problems with the accuracy settings that were resolved very quickly. Now we can proudly say that we can no longer imagine the production without the collaborative robot,” says Jiří Kašparec, production operator at 2D&S, s.r.o.
UR cobot models: UR10
04 THE Benefits
The UR10 collaborative robot has significantly accelerated the production of plastic moldings. Currently, the company uses a six-axis collaborative robot from Universal Robots on a single injection molding machine. At the same time, 2D&S s.r.o. continues to expand production, which will require the acquisition of at least two more collaborative robots.
05 THE Company
About MP Line, s.r.o. – System integrator
Many years of experience in the field of production automation, especially peripherals for injection molding machines, have led MP LINE to provide comprehensive and reliable solutions for streamlining manufacturing processes. By using modern technologies and methods, they can design and integrate the automation process into a variety of industries to ensure an efficient production process. One of the areas, where the company is operating is also the integration of Universal Robots solutions, where they became the first certified integrator of UR in the Czech Republic.
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Cost-effective, safe and flexible collaborative robots - or cobots - are making automation easier than ever, even for the small and mid-sized companies.