Automotive parts from Coko
16 different, complex automotive parts at an attractive price. To achieve this, an ARBURG turnkey system provides plastics processor Coko with the necessary efficiency and variance in production.
16 in one stroke
Fully automated
Two robotic systems handle 16 different components with up to 15 metal inserts each.
Qualitative
The application meets the automotive customer's 10 ppm requirement for premium quality.
Inexpensive
Thanks to full automation, complex parts can be produced at an attractive price.
Challenge
A total of 16 different components for truck door sills, including four functional or structural parts and twelve visible parts, needed to be produced fully automatically around the clock in a three-shift operation. With reduced manpower and consistently high quality. The turnkey system had to work with different injection volumes depending on the mould. There were also demanding quality specifications to meet, such as the 10 ppm requirement, where a defect rate of 10 per 1 million parts (max) had to be ensured.
Solution
A turnkey system based around a hydraulic ALLROUNDER 920 S with a clamping force of 5,000 kN is used. Four functional and structural components made of glass-fibre reinforced PA6 are overmoulded with up to 15 metal inserts in the mould. For this, up to five different inserters are separated simultaneously in the feed station. A KUKA robot places these in a loading platen. From there, a second robot picks up the inserts and, after removing the finished component, positions them simultaneously in both mould halves. After the injection moulding process, a check is made to ensure that all metal inserts are properly positioned in the component. Another twelve visible part variants without inserts are injection-moulded from PP (filled with 20% talcum), removed by the robot and subsequently transported to a clip assembly station, where they are fitted with up to eight clips in the "free-flying" gripper under the assembly head.
Conclusion
Variance, automation and the precision of the turnkey system offer a wealth of possibilities in the automotive segment. The result is high-quality interior components that meet the most stringent quality requirements yet can be manufactured cost-effectively and without finishing work.
“The high level of automation is critical in enabling us to offer the complex parts at an attractive price and to meet the highest quality requirements. ”
Sascha Böning, Industrial Engineering at Coko
Industry
Mobility
Technical parts, tactile parts, visual parts: are your plastic products – e.g. for interior, exterior, or other components for the automotive industry – precise, small, resilient or do they have demanding surfaces? Then you will have everything under control with our machine technology.
