Making complex connections

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

Plug insert

Forming and overmolding on a moving conveyor belt
Application example for flexible plug production: a compact production cell built around a vertical ALLROUNDER 375 V injection molding machine is being used for the automated overmolding 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 overmolding and forwarding to the injection mold. Inside the injection mold, each set of three contacts is overmolded to form a component assembly which is then separated from the stamped coil. Media-tight overmolding 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 reels for brake systems in automobiles: About 18,000 parts are produced per hour and separated according to cavities and boxed, ready-to-ship.

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

Sensor housing

Fully automatic stamping, bending and injection molding
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 palletizing station, are arranged around an electric ALLROUNDER 570 A injection molding machine. Two six-axis robotic systems work hand-in-hand. Three 4-cavity molds 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 encapsulated fully automatically
ARBURG has designed a production cell for the fully automatic volume production of internal conductors for Fakra connectors, encapsulating up to 72,000 pins per day. The associated robotic systems and peripherals are characterized by extremely fast and precise handling of the delicate inserts.

The production cell is built around a hybrid injection molding 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 mold. Here, the robotic system removes 16 finished parts and simultaneously inserts the pins. The cycle time is only approx. 20 s.
to the molded part

Rotary encoder

Complex electronic component
Three into one: A magnetic disc, carrier plate and protective cap are molded into a functional rotary encoder using the three-component process. The innovative mold 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 encapsulating with a carrier plate as well as magnetization and assembly injection molding directly in the mold. A fully automated production cell built around a hydraulic ALLROUNDER 370 S injection molding machine featuring three (0.5, 1.4 and 0.5 oz.) injection units.
to the molded part

Encapsulation of cables

High flexibility in the most confined of spaces
For the automatic encapsulation 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 encapsulated fully-automatically in several cavities, at different positions on a 4-cavity mold. The system is characterized 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 molded part