Automotive Success story

Punching parts, injection molding and assembly in a single cell

Customer benefits:
  • Compact manufacturing cell with minimal space requirement
  • Impressive process stability and availability
  • Reproducible quality within tight tolerance ranges
  • High productivity
Stäubli AG - injection-molding-engel-conti-tim-2x-55184-jpg-orig.jpg
Stäubli AG - 4-cavity-mold-engel-conti-tim-2x-55178-jpg-orig.jpg
The turntable reduces the cycle time and synchronizes the process. The 4-cavity mold is populated outside the clamping unit during the injection molding process.


Production of oil level sensors

Picking up punched parts and connectors, inserting delicate metal pins into a mold cavity, removing injection-molded casings from the cavity and clearing away the sprue. This whole complex operation is performed by four Stäubli robots during the production of oil level sensors.

Copper strip in rolls and plastic granulate are the basic materials. The final product is the sophisticated housing for the oil level sensor in a car. The housing is extremely thin-walled and 12 pins in five different versions have to be inserted in the injection mold. These protrude from the bottom of the component and differ both in their coating and in their shape. Three of the pins are diverted into the side connector, which requires them to be bent four times and cut. In addition, there are three sockets for mechanical attachment to the oil sump.



Three robots on a rotary tableh

The ready-to-connect housing is produced in a compact manufacturing cell that have been integrated into a plastic injection molding system with three servo eccentric presses, a rotary table and four Stäubli TS60 SCARAs.

Preparation and feeding of the inserts are synchronized by means of a central rotary table. Three of the SCARAs populate a four-cavity mold with inserts. These ultra-fast machines have to handle 60 metal inserts per cycle. In doing so, they directly access the belts issuing from the punching and bending unit, gather up the individual contacts there and insert them into the four cavities on the rotary table. For each of these, they required 15 inserts per housing and are pre-sorted so that the sophisticated gripper can pick them all up at the same time and place them accurately in the mold. Prior to placement, the camera system checks the pin set for completion so that, in the event of a fault, rejects are avoided.

The fourth