Insert Placing robot for Injection Molding machine using Clear core Motion Controller

Introduction

A 5-axis insert-placement robot, specifically engineered for injection molding machines, has been meticulously crafted and programmed utilizing a Clear Core motion controller. This sophisticated robotic system serves the critical function of precisely positioning inserts—small plastic components employed in chair legs to mitigate slipping on surfaces.

The manual execution of the insert-placement process by human hands is impractical and hazardous. It necessitates personnel to venture inside the operational mold, accurately positioning inserts within a tight timeframe of approximately 20 seconds—an inherently challenging task. The robotic solution adeptly addresses these challenges by efficiently retrieving four inserts from the designated feeder and depositing them into the mold cavity with exceptional precision and speed.

I am the sole developer of the comprehensive robot program, overseeing all facets of its implementation. The intricate wiring, crucial to the system's functionality, has been meticulously executed in accordance with my specifications.

Outlined below are the key components integral to the success of this innovative project.

Clear core motion controller from Teknic

The Clear Core motion controller, boasting a robust microcontroller, stands as a pivotal element in our system. Specifically engineered to govern both stepper and servo motors, this controller encapsulates all essential functionalities requisite for applications such as our advanced insert-placing robot.

The Clear Core controller is equipped with integrated I/O ports and four motor ports, facilitating precise control over stepper motors and servo motors alike. Employing C++ programming, the controller is configured through the Arduino Integrated Development Environment (IDE), adding a layer of versatility to the programming process.

In the context of our robotic application, three NEMA 23 stepper motors and a three-phase servo motor harmoniously come together to bring the insert-placing robot to life. The collective integration of these components underscores the sophistication and precision inherent in our robotic design.

HMI design and teaching function of the robot

The programming of this robot has been meticulously executed, harnessing the full suite of teaching functions. Every aspect of the robot's operation is seamlessly orchestrated through a Human-Machine Interface (HMI). The HMI integrates a Nexsion Intelligent Series Display, establishing communication with the controller via UART protocol.

Key functions, enhancing the versatility and control of the robot, are accessible through the HMI:

Coordinate Programming with Teaching Functions: Similar to conventional industrial robots, our system allows for intuitive coordinate programming facilitated by robust teaching functions.
Steps Execution Delay Control: Precise control over the execution speed between commands ensures optimal performance. This feature enables fine-tuning of the robot's movements for enhanced efficiency.
Acceleration and Deceleration Setup: The HMI facilitates seamless configuration of acceleration and deceleration parameters, contributing to the dynamic and controlled motion of the robot.
Sensor Monitoring and High-Priority E-Stops: Our system incorporates comprehensive sensor monitoring capabilities, coupled with high-priority emergency stop (E-stop) functionality, ensuring swift and efficient response to critical situations.
Custom Program Execution: The HMI empowers users to create custom programs, incorporating conditional statements (if-else commands). This capability allows for precise and tailored execution of instructions, enhancing the adaptability of the robot to diverse tasks.

The integration of these functions into the HMI underscores our commitment to providing a sophisticated and user-friendly interface for controlling and optimizing the performance of the insert-placing robot.

Three phase 0.75Kwh servo motor controlling and about delta electronics asd-b2-0721-b

The Z-axis of our robot, crucial for the precise movement of inserts within the injection molding machine, is controlled by a sophisticated servo motor and controller combination. This selection is driven by the imperative need for both precision and speed in moving the inserts, considering the constrained timeframe for their placement.

The servo motor chosen for the Z-axis is adept at meeting the stringent requirements of our application. It excels in precision and rapid movements, aligning seamlessly with the time-sensitive nature of insert placement. The accompanying controller enhances control and responsiveness, providing a robust solution for the dynamic demands of our operation.

Noteworthy features of this servo motor and controller combination include the ability to receive and process signals from various sources. Leveraging built-in PID functions, the controller ensures optimal performance in maintaining the desired position and velocity of the Z-axis.

To further optimize control, we have configured the controller in step direction mode, utilizing a 4KHz step frequency. This meticulous setup guarantees the efficient and accurate movement of the Z-axis, contributing to the overall success of our insert-placing robot within the injection molding process.

Panel Board Wiring & Design

This panel board consists of 3 stepper motor drivers, one servo driver, and a ClearCore motion controller with an I/O expansion board. All the stepper motors and the servo motor are controlled by the ClearCore motion controller, which was programmed using C++.

Note that this is not the final version of the panel board, and this picture was taken while wiring the panel board.

Working robot

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