Making complex connections

The electronics industry is characterised by a wide range of applications. Find out more about our individual solutions here: these include three-component and assembly injection moulding, automatic overmoulding of inserts and six-axis robots that combine stamping, bending and injection moulding.

Plug insert

Forming and overmoulding on a moving conveyor belt
Application example for flexible plug production: a compact production cell built around a vertical ALLROUNDER 375 V injection moulding machine is being used for the automated overmoulding of metal contacts. The MULTILIFT SELECT linear robot system is mounted compactly on the machine base.

An upstream stamping and bending cell supplies the pre-stamped metal pins on a reel for overmoulding and forwarding to the injection mould. Inside the injection mould, each set of three contacts is overmoulded to form a component assembly which is then separated from the stamped coil. Media-tight overmoulding of the contacts to complete the process and create a hybrid plug then takes place downstream.

Coil shells

How efficient high-volume production of technical parts can function is shown by the turnkey project for manufacturing coil shells for brake systems in cars: About 18,000 parts are produced per hour and separated according to cavity and boxed, ready-to-ship.

The heart of the production cell is a hybrid high-performance machine. In only 6.5 seconds, 32 coil shells are produced, which a rapidly operating robotic system removes within the cycle time and deposits via a special tube system into original parts boxes, separated according to cavity. The boxes are filled with an exact quantity.

Sensor housing

Fully automatic stamping, bending and injection moulding
ARBURG turnkey systems can be used for the high-quality serial production of complete functional units for cars. One example is the production of sensor housing covers for electronic accelerator pedals used in high-end vehicles. The complex system and all the upstream and downstream components are controlled centrally via the SELOGICA control system.

All production components, including a stamping/bending unit, gripper and testing technology, as well as a palletising station, are arranged around an electric ALLROUNDER 570 A injection moulding machine. Two six-axis robotic systems work hand-in-hand. Three 4-cavity moulds with replaceable inserts are used for a total of six housing cover versions. The positioning and orientation of the individual contacts are important tasks in every step. Furthermore, extensive optical and mechanical measures have been implemented for monitoring quality.

Internal conductors

Up to 72,000 pins overmoulded fully automatically
ARBURG has designed a production cell for the fully automatic volume production of internal conductors for Fakra connectors, overmoulding up to 72,000 pins per day. The associated robotic systems and peripherals are characterised by extremely fast and precise handling of the delicate inserts.

The production cell is built around a hybrid injection moulding machine whose electric clamping unit permits short cycle times. A vertical robotic system takes delivery of individual batches of 16 pins from two vibrating spiral conveyors. The pins are then inserted into the holes in the gripper insertion module and transported to the mould. Here, the robotic system removes 16 finished parts and simultaneously inserts the pins. The cycle time is only approx. 20 s.
to the moulded part

Rotary encoder

Complex electronic component
Three into one: A magnetic disc, carrier plate and protective cap are moulded into a functional rotary encoder using the three-component process. The innovative mould concept and the complex automation solution dispense with joining techniques and downstream assembly.

All operations are combined in a single process – including insertion of the sensor and overmoulding with a carrier plate as well as magnetisation and assembly injection moulding directly in the mould. A fully automated production cell built around a hydraulic ALLROUNDER 370 S injection moulding machine featuring three (size 30, 70 and 30) injection units.
to the moulded part

Overmoulding of cables

High flexibility in the most confined of spaces
For the automatic overmoulding of inserts, a compact production cell around a vertical ALLROUNDER 375 V is used. Handling of the flexible cables is performed by a six-axis robotic system. Manual preparation and insertion are rendered superfluous.

On the system, cables of differing lengths are inserted and overmoulded fully-automatically in several cavities, at different positions on a 4-cavity mould. The system is characterised by great flexibility, short cycle times and a high level of availability. Highlights of this application include the versatile handling of flexible parts and the six-axis robotic system featuring the SELOGICA user interface and direct connection to the machine control system.
to the moulded part