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For the complex manufacture of omni wheels, which have to meet the highest standards of dimensional stability, durability and efficiency, Omnia Wheel opted for a fully automated production solution. Working together with Comtec, Polarform and ARBURG, they developed a highly efficient production line that not only meets their quality requirements but also significantly reduces cycle times thanks to state-of-the-art injection moulding technology and robotics.
Significant time savings The fully automated production of the patented 50 mm wheel has resulted in significant savings – 33% less cycle time for axle production and as much as 43% for roller production.
Fully automated production Both the roller axles and the rollers with bushings are manufactured using 24-cavity moulds. Axles and rollers are assembled using a 12-cavity mould.
Successful joint project The production of the patented 50 mm wheel is something special, as it was automated as part of an overall project involving Comtec, Polarform and ARBURG.
The manufacture of omni wheels involves considerable technical requirements: their complex design calls for maximum dimensional stability, consistent quality and multidirectional rolling characteristics – even at high volumes. At the same time, they must be made from robust materials and feature shock-resistant components to guarantee a long service life. In a dynamically growing market like logistics automation and robotics, short cycle times and fully automated series production are also essential to stay competitive.
To meet these demanding requirements, Omnia Wheel uses a fully automated production line, which was implemented in close cooperation with Comtec, Polarform and ARBURG. Modern ALLROUNDER injection moulding machines are at the heart of production, efficiently manufacturing both large wheels with diameters of 90–180 mm and the particularly complex 50 mm wheel. The axles are produced on an ALLROUNDER 520 E, and the rollers with bushings on a two-component ALLROUNDER 630 S. The components are assembled by a precisely coordinated high-speed automation system with Stäubli robots, while a MULTILIFT robot transfers the assemblies to another ALLROUNDER 570 S for overmoulding and final pressing. The result: 33% shorter cycle times in axle production and savings of 43% in roller production at consistently high quality levels and with maximum process reliability.
“The large number of parameters that can be monitored with the ALLROUNDER machine controller was a decisive factor in achieving our goals.”
Jochen Werner, Omnia Wheel Moulding Manager
A complete solution from a single source and reliable comprehensive service convinced Omnia Wheel – and laid the foundations for a long-term partnership. Following the successful start of the project, the next steps have already been taken: together with Comtec and ARBURG, Omnia Wheel is actively pushing ahead with the planning and implementation of additional machine investments.
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