Programming a 3-Axis Servo Injection Robot: Step-by-Step Guide

Robot tooling selection must consider component weight, gripper weight, adapters, and robot payload capacity. There is no standard robot flange for different gripper sizes, so adapter plates are often needed, which adds weight and reduces payload. Environmental factors like IP ratings are important considerations. Finger length affects moment on the robot's base, and adequate force must be available to hold components securely. Robot and machine communication uses various protocols including Ethernet IP (most popular modern option) and hard-wired interfaces for older machines (24-volt signals for cycle start, door switches). For machines without sophisticated controls, integration can monitor stack lights to detect cycle readiness and use pneumatic devices to replace manual actions. EUROMAP 67 interfaces robots with injection molding machines. The key is understanding that older machines can be automated but may require running more hours than originally designed.

This segment details the electrical integration process for connecting robots to injection molding machines. The Euromap 12 interface standard is used for robot-TPA communication, involving connector installation, cable routing through the machine frame, and controller wiring. Intermediate relays facilitate signal exchange between machine and robot controllers. The robot for insert preparation is mounted on a dedicated table near the machine, connected to compressed air from the workshop's pneumatic system. The control panel is connected using signal wires to enable communication between the five-axis robot and the insert preparation robot. All connections are verified against schematics to ensure proper system integration.

This video demonstrates how the Safety Simplifier wireless safety PLC with integrated Euromap 78 interface enables simplified plug-and-play safety integration for injection molding machines, reducing planning and wiring effort while achieving PLe safety level through secure wireless or CAN communication with safety switches.

Euromap 12 is a worldwide communication protocol between injection molding machines and robots. It was developed to address communication issues between machine manufacturers and robot manufacturers. This protocol enables seamless communication between the machine and robot, allowing them to coordinate operations safely and efficiently without requiring complex custom interfaces.

The robot interface plug serves as a critical communication bridge between the robot and injection molding machine, transmitting relay signals for coordinated operation. This interface enables essential functions such as mold opening, ejector activation/deactivation, and robot movements including entering the mold, part grasping, and traversing out of the mold. The interface ensures safe, reliable, and repeatable part removal sequences by allowing the robot to inhibit mold movement until it reaches the correct position before signaling ejectors to move and place parts in designated positions.

Players can purchase automation equipment including conveyor belts, scanners, and sorting machines. These upgrades require significant investment and may need additional licenses. Conveyor belts can automatically scan package information and route packages to appropriate destinations. Scanners can verify weight and serial numbers automatically. The integration of multiple automation systems creates a more efficient workflow, reducing manual verification time.

Automated systems combine multiple sensor inputs to classify parts: (1) A part present sensor initiates the sorting cycle, (2) A stopping piston holds the part at the sensor location, (3) Color sensors and magnetic sensors work together to identify the part type, (4) Based on sensor combinations, the system determines which gate to activate, (5) The conveyor belt continues moving while the piston retracts and the appropriate gate opens, (6) Chute sensors confirm successful routing and trigger system restart.

Finished product conveyors should only run when there is a downstream call (parts are needed at the next station). The system uses an unused input as a downstream call push button. Conveyor control logic checks both downstream call status and photo eye 3 detection. If conditions are met, cylinder 5 extends to stop parts; otherwise, the conveyor stops. This prevents running the conveyor when no parts are needed, saving energy and preventing accumulation. The system latches completion bits to track each step, and the reset function clears all latched bits and outputs, returning the machine to its initial state for continuous operation.

This segment covers warehouse automation and conveyor belt systems. The player learns to purchase and install conveyor belts, scanners, and sorting machines to automate package processing. The segment demonstrates how automation systems can be designed to route packages based on their status, with pre-approved packages following one path and denied packages following another. The player implements a sequential verification pipeline where packages pass through multiple scanning stations (serial number, weight class, country validation) before reaching their destination. The segment also covers creative positioning techniques for conveyor belts and system optimization through upgrades.

Integrating vision systems with conveyor tracking involves: (1) Using the controller to send digital output triggers to the camera at regular intervals based on conveyor position, (2) Looping back the camera trigger signal as a latch to record the conveyor position when each snapshot is taken, (3) Monitoring Ethernet/IP data from the camera for new part information, (4) Waiting for new data flags to arrive, (5) Combining latched positions with vision data to create buffered part records. This enables processing of multiple parts with varying positions and orientations.

This extended process covers handling fault conditions and final system calibration. When faults occur (e.g., from excessive speed), the drive displays 'lost faith' and the motor unlocks. Recovery requires: (1) Powering down the drive; (2) Waiting a few seconds; (3) Powering back up; (4) Re-establishing communication by clicking 'connect' and selecting the COM port; (5) Re-reading drive parameters and verifying 'on position' status. After successful recovery, the system is ready for final calibration using the auto tuning feature in version Fe 471. This feature should be used after configuring control software, setting access limits, and installing limit switches and end stops. The complete workflow ensures the servo system is properly calibrated before full machine operation.

The test encoder program verifies servo feedback cable connections by checking indicator lights (P26 for left wheel, P27 for right wheel). When rotating each wheel, the corresponding light should blink—if lights are swapped, the yellow feedback cables are reversed and must be swapped. The program loads to EEPROM and runs automatically when power is set to position 2. Calibration teaches the robot its exact wheel positions and movements by loading the calibration program, setting power to position 2, and waiting for the robot to lurch forward and spin in place in both directions. Successful calibration is indicated by a success tone and indicator lights turning off. The program destroys itself after running to prevent accidental recalibration. Troubleshooting common issues: backward movement indicates swapped servo cables, shaking with error tone indicates electrical problems, and power supply issues may stem from weak batteries or incorrect power pin connections.

Failed calibration is indicated by the robot twisting back and forth with yellow LEDs remaining on. Common causes include miswired motors or encoders. Troubleshooting steps include: disconnecting USB, turning robot off, moving switch to position 2, and pressing the blue reset button. To verify wiring, pull on servo leads while turning the robot upside down to identify which wire belongs to which motor.

Motor speed is tuned using 'Forward Speed Time' with speed set to 40 and time to 1500ms. Test on the field and adjust 'Initial Speed' values if the robot drifts (increase value for slower wheel). For servos, connect to Servo 1 and Servo 2 ports with black wire on outer side. Test grip angle starting at 70 degrees (default 50), decreasing in increments of 5 until secure but not too tight. Test down angle (default 140) so gripper is parallel to ground but not touching. To measure sensor values: press and hold OK for 3 seconds to measure black (values 1000-2000), press OK once for white (values around 4000), press OK again for average. Repeat for all 7 front sensors (A0-A6) and 2 rear sensors. Enter these values in the 'Average' column in the program. This measurement is necessary when the robot is assembled for the first time or when sensors are repositioned, as values may change.

Robot axis and encoder calibration involves aligning physical calibration marks (muescas) on each axis to establish accurate position references, then using software to update the revolution counters; when encoders fail due to power loss or excessive force, the robot's position data becomes invalid, requiring this calibration process to restore accurate movement capabilities for world and reorientation movements.

Effective five-axis programming involves strategic planning of tool paths and orientations. The approach typically includes: (1) Establishing reference planes through rotation to transform rectangular stock into triangular profiles, (2) Using larger face mills (3-inch wide) for efficient roughing of wide stock sections, (3) Rotating the part 90 degrees to establish additional faces, (4) Using smaller tools (0.5-inch end mills) for detailed profiling including pockets through ribs, (5) Maintaining consistency with three-axis tool paths where possible, and (6) Utilizing specialized tools like 45-degree chamfer mills and back chamfer tools for hard-to-reach areas.

A gantry robot is a Cartesian coordinate robot that achieves three-dimensional movement (X, Y, Z axes) through independent motor-driven linear slides, where positive and negative numerical values control directional movement along each axis, and the system can be programmed using software like MATLAB to receive commands via serial communication, with motor drivers converting these signals into clockwise or counterclockwise motor rotation to precisely position tools or grippers for pick-and-place operations.

Five-axis machines are primarily used as enhanced three-axis machines that can easily reposition between operations. This capability significantly reduces the number of setups required compared to traditional three-axis machining. In three-axis machining, hitting all six sides of a complex part typically requires six separate setups where the part must be removed, rotated, repositioned, and refixed. For intricate parts with odd shapes that are difficult to grasp during subsequent operations, five-axis machining allows completion in far fewer steps by repositioning the workpiece rather than removing it.

Five-axis CNC programming requires a fundamental shift from traditional three-axis approaches. Instead of programming operations one at a time, five-axis programming involves programming the entire part simultaneously across all five axes. However, modern five-axis controls are designed to make this transition easier by allowing programmers to use similar techniques as three-axis programming, simply adding the rotational axes. The machine's ability to remember its zero position on the fourth and fifth axes significantly simplifies the programming process, making five-axis machining more accessible to experienced three-axis programmers.

Five-axis machining significantly reduces the number of setups required to complete complex parts compared to three-axis machining. In the example shown, a part that would require four separate setups on a three-axis mill can be completed in just two setups using five-axis capabilities. This reduction in setups minimizes the chances of errors during part repositioning and reduces overall cycle time.