35 percent lighter than its predecessor, much more stable and decorative - we are talking about a nutcracker.
What may sound unspectacular at first glance, requires a lot of know-how in automated production. (Source: M.A.i)


Innovative, highly complex and fully automated processes combined in a single solution, where previously a large number of individual production steps would have been necessary - this is the Core competence of the automation expert M.A.i. Using the example of production of a nutcracker, the company shows what can be achieved in interaction with strong partners like Yaskawa in the field of automation solutions.

35 percent lighter than its predecessor, much more stable and decorative - we are talking about a nutcracker. What may sound unspectacular at first glance is a real world first. After all, the innovations in the manufacture of the practical household helper, which Kronach-based automation expert M.A.i GmbH & Co KG presented for the first time at Fakuma 2015, were a genuine trade fair highlight.
In cooperation with its partners Sumitomo (SHI) Demag, HBW-Gubesch, KURZ and Yaskawa, the special machinery manufacturer M.A.i implemented an innovative and at the same time complex automation solution for insert molding and back-injection of UD tapes in the production of the Nutcracker - thus demonstrating the successful integration of lightweight construction, decoration and assembly technology, as required for visible parts in vehicles, for example.
To improve stability, a three-layer UD tape reinforces the nutcracker. In contrast to organic sheets, which usually consist of fiber mats arranged at an angle of 90 degrees, the tapes have unidirectional ("UD") oriented continuous glass fibers and offer a greatly increased tensile strength in the direction of the fibers. Components can be reinforced in line with the stresses to which they are subjected by means of targeted placement.
The ribbed structure is made of the plastic PP-GF30 (type Fibremod from Borealis). The wall thickness was reduced from 4 to 3 mm. The toothing is integrated into the back injection as a wave contour. This has made it possible to significantly reduce the weight.

Robot-based hot handling
The manufacturing cell for producing the nutcracker is directly connected to a Demag Systec Servo 210 injection moulding machine from Sumitomo. Other components include a 6-axis Motoman MH12 handling robot from Yaskawa with a multiple gripper system, the hot handling system for UD tapes developed by M.A.i and removal stations for the decorative foils and metal inserts. Hot-Handling describes a heated gripper system that is used to control and regulate the heating process of the UD tapes until they are directly inserted into the tool. The advantages of the hot handling process are shorter process times and gentler and more targeted temperature control. In addition, a heating and removal station for the UD tapes, a cutting station for sprue separation and an assembly and riveting station for connecting the two halves of the nutcracker are integrated.
In the manufacturing process, the robot picks up the film insert, the inserts and the UD tape with the help of the hot handling process and moves directly into the opened mould of the injection moulding machine. There the finished part is removed from the cavity. The robot then positions the foil insert, the UD blank and the metal inserts one after the other. Where previously individual production steps would have had to be carried out by hand and possibly subsequent assembly work, M.A.i can now offer a fully automated solution for the first time.

Motoman MH12 plus DX200 - convincing performance
In deciding in favour of the Motoman robot, those responsible at M.A.i were not only convinced by the fact that Yaskawa was able to provide a suitable solution for the trade fair application quickly and easily. Also the high innovative power and the convincing basic data of the MH12 made the choice easy. The 6-arm robot used in the production cell is particularly distinguished by its speed. The high-speed robot is designed for a load capacity of up to 12 kg. In order to improve the media feed to the gripper, the MH12 from Yaskawa has a hollow wrist with a diameter of 50 mm. This significantly reduces the mechanical stress on the cables. Possible connection faults are eliminated, thus simplifying programming and maintenance of the robot.
The slim, streamlined design of the articulated arm robot not only reduces interfering contours between the machine and the workpiece. It is also consistently space-saving, allowing handling in confined spaces and a high robot density. The DX200 controller used is also innovative and particularly user-friendly. Compared to the previous generation, the latest generation controller offers additional safety features and over 120 application-specific functions. With the "activeRemote" production efficiency module, the entire robot and peripheral technology has been integrated into the injection moulding machine controller. This meant that the entire production cell could be controlled via a single user interface.
This means that production and process data can be easily recorded, processed and visualized even in the most complex automation applications. In addition, it is also possible to control the partner systems via the user interface of the injection moulding machine. Before unnecessary rejects occur, faults in the production process become visible and can be eliminated in good time. This saves time and money.

 
Conclusion
With his direct to the production cell connected to the injection moulding machine is proven by the special machine manufacturer M.A.i once again demonstrates its high level of competence in of highly complex automation solutions. A Motoman handling robot from Yaskawa's efficient and intelligent production process of a nutcracker numerous process steps.

The manufacturing cell for producing the nutcracker is directly connected to a Demag Systec Servo 210 injection moulding machine from Sumitomo.
Further components are: a 6-axis handling robot Motoman MH12 from Yaskawa with multiple gripper system,
the hot handling system developed by M.A.i for the UD tapes as well as removal stations for the decorative foils and the metal inserts. (Source: M.A.i)