Peripheral Robots and Injection Molding Cell Automation - Complete Guide 2025

Introduction to injection molding cell automation

In the dynamically changing world of plastics production, injection molding cell automation has ceased to be an option and has become a fundamental requirement for competitiveness. According to PARP's "Industry 4.0 in SME Practice" report from 2023, as many as 62% of Polish processors indicate a shortage of qualified operators as a key growth barrier. Facing these challenges, peripheral robots and integrated automation systems are no longer a luxury, but a strategic necessity ensuring production stability, quality repeatability, and cost advantage.

IFR's "World Robotics 2023" study shows that the chemical and plastics industry already accounts for 6% of all robotic installations in Europe, with the upward trend accelerating year on year. Tederic injection molding machines from the DE, DH, and NE series cooperate seamlessly with robots, vision systems, and peripheral equipment, creating new-generation integrated injection molding cells. Properly designed injection molding cell automation can reduce cycle time by up to 40%, eliminating process bottlenecks.

What is injection molding cell automation?

Injection molding cell automation is a comprehensive, integrated system of devices, software, and engineering solutions that fully or partially automate the plastic injection molding process and ancillary operations. It covers all production stages - from raw material preparation, through the injection process itself, to finishing operations and quality control of finished parts.

A modern injection molding cell can include the following key components: manipulative robots (pick-and-place, 3-axis, 6-axis, SCARA or cobots), transport and quality control systems (2D and 3D cameras), automatic material feeding and drying systems, cooling systems with temperature control ±0.1°C, mold temperature controllers, and integrated SCADA control systems communicating via Euromap and OPC-UA standards.

According to Euromap and VDMA's "Automation in Injection Moulding Cells" 2023 report, comprehensive automation with pick-and-place robots and vision systems allows achieving cycle time reduction of 20-30% compared to manual operation, with simultaneous increase in part quality repeatability.

Types of peripheral robots

Choosing the right type of injection molding robot is a key decision determining automation success. Each robot type has specific features, advantages, and limitations that must be confronted with actual production requirements.

Pick-and-place robots

Pick-and-place robots represent the most popular solution in injection molding cell automation. They feature simple kinematic construction, usually based on three linear axes (X, Y, Z). Portal or crossbeam construction is mounted directly above the injection molding machine, minimizing occupied production space.

Advantages of pick-and-place robots:

• Highest positioning repeatability - accuracy up to ±0.05 mm, crucial for precise stacking
• Extremely short cycle time - from 0.8 to 2.5 seconds depending on part mass and distance
• Lowest investment cost - from 15,000 EUR with gripper and programming
• Intuitive programming - new parts in 15-30 minutes
• High reliability - over 50,000 hours of failure-free operation

Disadvantages of pick-and-place robots:

• Limited kinematic flexibility - difficulty with complex spatial manipulations
• Limited payload - typically 0.5-5 kg, maximum 15 kg
• No secondary operations capability - only pick-and-place
• Overhead space required - problematic in low-ceiling halls

Six-axis robots (6-axis industrial robots)

Six-axis robots represent the highest level of automation flexibility. Construction based on six rotary axes enables achieving practically any position and orientation in the workspace.

Advantages of six-axis robots:

• Full kinematic freedom - any position with any tool orientation
• Wide payload range - from 3 kg to 210 kg
• Precise trajectory control - repeatability up to ±0.03 mm
• Multi-task operation capability - removal, inserts, assembly, labeling in one cycle
• Application versatility - quick tool change and reprogramming

Disadvantages of six-axis robots:

• High investment cost - from 40,000 EUR to over 150,000 EUR
• Complex programming - requires 3-5 days of training
• Larger space occupied - challenging in densely packed halls
• Longer cycle time - 30-50% slower than dedicated pick-and-place

SCARA robots (Selective Compliance Assembly Robot Arm)

SCARA robots are a specialist category designed for ultra-fast operations in the horizontal plane. Construction based on two parallel rotary axes and one vertical axis provides stiffness in the vertical direction while maintaining flexibility in the horizontal plane.

Advantages of SCARA robots:

• Highest operation speed - cycle in 0.3-0.8 seconds
• Exceptional precision - repeatability up to ±0.01 mm
• Compact construction - weight 30-60 kg, easy installation
• Low operating costs - energy consumption 0.4-1.2 kW

Disadvantages of SCARA robots:

• Limited vertical movement range - typically 200-400 mm
• No tool orientation - always vertically downward
• Limited payload - typically 1-20 kg

Cobots (collaborative robots)

Cobots represent a revolutionary approach to automation, where the robot is designed for direct and safe cooperation with humans. Advanced sensory systems enable immediate stopping when contact with an operator is detected.

Advantages of cobots:

• Highest safety level - 150N force limit according to ISO/TS 15066
• Minimal installation requirements - no need for fencing
• Intuitive programming - by "hand guiding" method
• Low entry threshold - from 25,000 EUR
• Human-robot collaboration capability - production flexibility

Disadvantages of cobots:

• Limited speed - 250-1000 mm/s limits cycles by 40-80%
• Smaller payload - typically 3-20 kg, rarely 35 kg
• Precision compromise - repeatability ±0.05-0.1 mm
• Limited reach - 500-1300 mm

Peripherals and additional equipment for the injection cell

A modern injection molding cell is much more than a robot and injection molding machine. Peripherals constitute a critical element of the production ecosystem, often determining final efficiency and quality. Peripheral optimization can bring up to 25% reduction in operating costs.

Key peripherals include:

• Material preparation systems - absorption dryers with dew point to -40°C, central loaders, blending stations with ±0.5% accuracy, regrind mills
• Temperature control systems - precision chillers ±0.1°C, multi-zone mold temperature controllers, hot runner systems
• Quality control systems - 2D/3D cameras, reject systems, dynamic scales with 0.01 g accuracy
• Transport systems - belt conveyors, inter-operational buffers, vibratory orientors, automatic packaging systems

Control integration and communication standards

The key to effective injection molding cell automation is seamless communication of all devices. Tederic injection molding machines from the DE, DH, and NE series are equipped with state-of-the-art controllers supporting all key industrial communication standards.

Euromap 12 - basic standard defining electrical interface of 8 input and 8 output signals between injection molding machine and robot (readiness, mold opening, cycle start, alarms). Tederic offers Euromap 12 as standard, ensuring compatibility with robots from Star Seiki, Yushin, Wittmann, Sepro or Engel.

Euromap 67 - modern serial communication protocol RS-232 or Ethernet, enabling bidirectional exchange of process, diagnostic data and messages in real time. Allows remote robot programming from the injection molding machine panel.

OPC-UA - universal Industry 4.0 standard for data exchange in IoT architecture. Tederic injection molding machines with OPC-UA option can publish hundreds of parameters to MES, ERP, SCADA systems without additional converters. Provides full production transparency and advanced analytics capability.

Key technical parameters for robot selection

Choosing the right robot requires analyzing key technical parameters and confronting them with actual application requirements.

1. Robot nominal payload (kg)

Maximum mass the robot can safely carry, including gripper, part and additional tools mass. Apply the 150% reserve rule - if part weighs 3 kg and gripper 1.5 kg, choose robot with minimum 7 kg payload. Typical ranges: pick-and-place 0.5-15 kg, SCARA 1-20 kg, 6-axis 3-210 kg, cobots 3-35 kg.

2. Working reach / action radius (mm)

Maximum distance the robot can reach from mounting base. Must cover entire work zone: from mold center through drop-off zone to secondary operation stations. Typical ranges: pick-and-place 400-1500 mm, SCARA 400-1000 mm, 6-axis 500-3100 mm, cobots 500-1300 mm.

3. Positioning repeatability (mm)

Key parameter defining accuracy of returning to the same position after multiple cycles. According to ISO 9283: pick-and-place ±0.05-0.1 mm, SCARA ±0.01-0.02 mm, 6-axis ±0.03-0.08 mm, cobots ±0.05-0.1 mm. For IT7-IT8 tolerances required <0.05 mm.

4. Maximum speed / cycle time (mm/s or s)

Movement speed directly translates to cycle time. For short injection cycles (2-5 s) choose fastest pick-and-place (0.8-1.5 s/cycle). Typical speeds: pick-and-place 2000-4000 mm/s, SCARA 5000-10000 mm/s, 6-axis 1000-2500 mm/s, cobots 250-1000 mm/s.

5. IP protection rating (Ingress Protection)

Standard robots have IP54 (dust protection, water spray protection). For wet environments choose IP65 (jet protection) or IP67 (immersion resistance).

6. Operating ambient temperature (°C)

Standard range is +5°C to +45°C. For unheated halls choose extended versions -10°C to +55°C. For hot environments required high-temperature versions up to +60°C.

7. Life cycles / MTBF (cycles or hours)

High-class robots designed for 1-2 million cycles or 50,000-80,000 hours before major overhaul. At 24/7 and 10 s cycle robot performs ~3 million cycles annually.

Industry applications of injection molding cell automation

Automotive industry - door panels, consoles, engine covers, LED lighting parts. Requirements: full automation, 100% visual inspection, 6-axis robots 15-50 kg, repeatability <0.05 mm, cycles 30-90 s.

Consumer electronics and home appliances - smartphone housings, laptop cases, TVs, small appliances. Requirements: changeover flexibility, vision systems detecting scratches, cycles 15-45 s, high surface aesthetics.

Medical industry - syringes, infusion systems, portable diagnostics. Requirements: production in ISO 7-8 cleanrooms, stainless steel robots, 100% documentation, USP Class VI biocompatible materials.

Packaging and food industry - closures, cups, containers, disposable cutlery. Requirements: ultra-fast pick-and-place (0.8-2 s), multi-cavity molding (16-96 cavities), IML systems, food-contact approved materials.

Electrical industry - switch housings, junction boxes, connectors, LED fixtures. Requirements: flame-retardant materials UL94 V-0, insert molding with metal inserts, electrical properties control, VDE, UL, CSA certifications.

How to choose robots and peripherals for your cell?

Choosing the optimal automation set requires systematic analysis of many factors.

Part and process characteristics: part mass, geometry, material, dimensional tolerances, aesthetic requirements.

Production parameters: annual volume, injection cycle time, number of models, operating mode (24/7 or shifts), ROI assumptions (typically 18-36 months).

Space constraints: available space around injection molding machine, ceiling height, media availability (400V, compressed air 6-8 bar), environmental conditions.

Integration requirements: injection molding machine compatibility (Euromap, OPC-UA), MES/ERP integration, peripherals to integrate, future expansion possibilities.

Team competencies: programming experience, 24/7 service availability, spare parts availability, application support, Total Cost of Ownership over 10 years.

Maintenance and upkeep of peripheral robots

Proper maintenance is the foundation of long-term, failure-free operation. Systematic preventive maintenance can extend failure-free operation time by 40-60% and reduce unplanned downtime costs by 70-80%.

Daily tasks (5-10 minutes):

• Visual inspection of gripper and suction cups
• Cleaning robot end effector from dust and contamination
• Pneumatic lines and cables inspection
• Verification movement test without part
• Cleaning vision system camera lenses

Weekly tasks (30-45 minutes):

• Thorough external cleaning and ventilation openings
• Mechanical clearance and bolted connections inspection
• Grease level check in automatic lubrication systems
• Precision verification at reference points
• Pneumatic pressure control, condensate drainage
• Configuration programs backup

Monthly tasks (2-3 hours):

• Guides and joints lubrication with NLGI 2 lithium grease
• Power cable inspection, terminal tightening
• Moving parts wear inspection
• FRL filter cleaning or replacement
• TCP (Tool Center Point) calibration
• Safety systems testing (STOP, light curtains, locks)
• Event log and alarms review

Annual tasks (major overhaul, 1-2 days, authorized service):

• Comprehensive mechanical inspection - bearings, gearboxes, belts
• Joint clearance measurement and wear assessment
• Electrical inspection - winding insulation resistance
• Grease, seals, filters, controller batteries replacement
• All axes recalibration with measuring equipment
• Firmware and security patches update
• Technical report with condition and recommendations

Consumables requiring regular replacement:

• Mechanical grippers - every 500,000-1,000,000 cycles
• Vacuum suction cups - every 200,000-500,000 cycles
• Pneumatic seals - every 12-24 months
• FRL unit filters - every 3-6 months
• Controller batteries - every 24-36 months
• Greases and oils - replenishment every 6-12 months

Summary

Injection molding cell automation using peripheral robots is not the future, but the present of modern, competitive plastics production. Facing shortage of qualified operators, growing quality requirements and pressure to reduce costs, comprehensive injection molding cell automation becomes a key success factor.

Key findings from the guide:

• Diversity of robotic solutions - from simple pick-and-place through flexible 6-axis robots to collaborative cobots, each type has its optimal application
• Cycle time reduction up to 40% - comprehensive automation with robots and vision systems can shorten cycle time by 20-30%, and with peripheral optimization even by 40%
• ROI in 18-36 months perspective - considering labor cost savings, scrap reduction and OEE increase
• Holistic cell approach - success requires peripherals, control systems, transport and data management integration
• Communication standardization - Euromap 12/67 and OPC-UA are foundations of plug-and-play integration of different manufacturers
• Safety and ergonomics - cobots enable safe human-robot collaboration, increasing flexibility
• Preventive maintenance is key - can extend failure-free operation time by 40-60% and reduce downtime costs by 70-80%

Choosing the optimal automation solution requires in-depth analysis of part characteristics, production parameters, infrastructure constraints and long-term business goals. There are no universal solutions - each application is unique and requires individual engineering approach.

If you are planning injection molding cell automation or robotization implementation, contact TEDESolutions experts. As an authorized Tederic partner, we offer comprehensive consulting on robot and peripheral selection, cell layout design, control system integration, turnkey solution implementation and full technical and service support.

See also our articles on automation and Industry 4.0 in plastics processing and contract molding services and contract manufacturing.