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1M/us/05-2002/dm
>> One has to do whatever he is presently doing, with such an intesity, that it puts him in the
position to break through the barrier of sound. << Luigi Colani (Designer)
be the first.

Innovative injection molding technology

robots
ENGEL ROBOTS.
Precision automation for the injection molding machine.

>>

2
>> >>

>> >>
>> Automated handling of molded parts for
increased productivity and improved quality.
A production process is only as good as the sum of its
individual parts. In other words, performance and quality
must not be left to chance at any stage of the process.
For the injection molder, this means controlled, i.e.
automated, handling both upstream and downstream of
the molding operation. Upstream – for the insertion of
components into the mold; downstream – for the removal
of the molded part and its transfer to other stations for
further processing. All of these handling operations must
be performed rapidly, efficiently, reliably, continuously
and, moreover, at relatively low cost. And it is precisely
these requirements which Engel robots meet. Engel robots
– precision automation for the injection molding machine.
3
>> >>

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ENGEL ROBOTS.
The right robot for every application.

ERC 23 - 53 E, EA, EH 63 - 83 E, EH 94 - 144 E

For injection molding machines: US

(clamp force in US tons) tons 40 - 750 250 - 2000 1500 - 6000

Demolding stroke X mm 300 - 700 700 - 1300 1300 - 3000

Vertical axis Y mm 600 - 1600 1000 - 2200 1800 - 3000
Horizontal axis Z mm 1400 - 5720 1880 - 8120 2360 - 9920

Max. handling weight ibs 6.6 - 22.0 44.1 - 66.1 66.1 - 176.4
(parts + gripper)

Max. speed (Y-axis) m/s 2

Asynchronous servo drive EA
Servo drive E m/s 3 3 2,5 - 3
High-speed drive EH m/s 5 4
4 Repeatability mm ± 0,05 ± 0,05 ± 0,1

ENGEL ERC 83 E
ENGEL ERC 23 - 53 E (alter native ENGEL ERC 63 - 83 E, EH
options EA and EH) – Fast and flexible The Power Class
- R a t e d f o r in jection mol d i ng ma c hi ne s w i t h - Ra te d fo r i nj e c ti o n m o l di ng m a c hi ne s w i th
cl ampin g f orces o f b e t w e e n 40 – 750 U S t ons. c l a m pi ng fo rc e s o f be tw e e n 2 5 0 a nd
- Av a i lable with a choi c e of t hre e d i ffe re nt 2 0 0 0 U S to ns.
d r i v e var ian ts : - Particularly sturdy mechanism for the handling of
> A sync hronou s servo drive (EA) w e i g hts up to 3 0 k g ( 6 6 l bs. ) .
for lo n g an d me d i um c y c l e t i me s - Servo drive (version E) providing linear speeds of
> S e rvo d rive ( E) up to 3 m / s w he n ha ndl i ng a w o rk i ng l o a d
for f as t to tal cycl e t i me s ( hi ghl y d y na mi c ) o f 6 6 l bs.
> High -sp e e d d ig ital servo drive (EH) - H i g h spe e d v e rsi o n ( EH ) w i th di g i ta l se rv o dri ve
for extremely fast parts removal (demolding times c a pa bl e o f l i ne a r spe e ds o f 4 m / s
as f as t as 0.5 s e c w he re t he t ot a l c y c l e t i me i s w he n ha ndl i ng a w o rk i ng l o a d o f 4 4 l bs.
on ly 5 s ec) - Pre c i si o n a nd re pe a ta bi l i ty w i thi n a to l e ra nc e o f
± 0 . 0 5 m m , a s w i th the EN G EL ERC 2 3 – 5 3 ,
- P recis io n an d repea t a b i l i t y w i t hi n a t ol e ra nc e the re fo re sui ta bl e fo r i nse rt- pl a c i ng a nd
o f ± 0.05 mm. a sse m bl i ng o pe ra ti o ns.
- M ach in e / robo t m ount i ng i nt e rfa c e on - Al l EN G EL ERC m o de l s a re g e ne ra l l y c o m pa tib l e
st at ion ar y platen . w i th suc h c y c l e ti m e re duc ti o n m e tho ds a s
- M o l d ed par ts can b e d e p osi t e d on e i t he r t he a dv a nc e re spo nse , sy nc hro ni z e d po si ti o ni ng ,
o p er ato r or n on - op e ra t or si d e of t he i nj e c t i on pa ra l l e l o pe ra ti o n, e tc .
m o l d in g mach in e, or, a t t he e nd of t he ma c hi ne i f
t he ro bo t is in s tall e d t o op e ra t e a l ong t he
l o n gitu din al mach i ne a xi s.
- M o d u lar s ys tem f or fl e xi b i l i t y of a xi a l l e ngt h.
- Co m pact des ign e nsuri ng l ow ov e ra l l ENGEL ERC 94 - 144 E
m ach in e h eig h t. The power package for large
- Vertical axes also available in tandem arrangement,
i f requ ired.
injection molding machines
- Ra te d fo r use o n l a rg e - c a pa c i ty m a c hi ne s w i th
c l a m pi ng fo rc e s upw a rds o f 1 5 0 0 U S to ns.
- Axe s a m pl y di m e nsi o ne d fo r e xtre m e sta bi l i ty.
- C o m pa c t c o nstruc ti o n.
- Se rv o m o to r dri v e s o nl y.
- Te l e sc o pi c v e rti c a l a xi s i s sta nda rd.
- H e l i c a l ra c k - a nd- pi ni o n dri v e s, sturdi l y bui l t a n d
pe rm a ne ntl y l ubri c a te d fo r l o w - no i se o pe ra ti o n .
- Spe c i a l se que nc e c o ntro l so ftw a re fo r the
synchronized operation of robot and machine – a
valuable cycle time saving feature when demolding
” de e p- dra w ” pa rts.
01
Hardened and ground precision guideways mounted on a
sturdy frame and operating in conjunction with precision
drive technology guarantees a positioning accuracy to
within ± 0.05 mm.

02 03 04 05
The rack-and-pinion drives All Engel robots are Minimum changeover times The clearly arranged display
are permanently lubricated equipped, from size ERC 63 thanks to a rapid-action of vacuum and comp ressed
for long service life and upwards, with a telescopic coupling system mounted air circuits, and the simple
minimum maintenance. vertical axis as standard, directly on the vertical axis. means of switching over from
thus keeping the overall vacuum to compressed air
height of the machine within and vice versa, considerably
an acceptable limit. reduces the work of setting
The double guide system up and adjusting the robot.
ensures optimum rigidity.
 7

Maximum efficiency in injection molding – with Engel robots:

> ”Time is money – and quality is a matter of course” – this is the concept
behind the design and specification of all Engel robots.

> ENGEL ERC linear robots are available for injection molding machines with
clamping forces of between 40 and 6000 US tons.

> Engel robots can be used not only with all makes and models of injection
molding machines, but also for production and handing applications in other
branches of industry.

> Full integration of the ENGEL ERC robot sequence control in the control
system of the Engel injection molding machine significantly shortens the
cycle time.

> ENGEL ROBOTS are fast and accurate: linear speeds of up to 5 m/s and
positioning tolerances of within ± 0.1 mm (small and medium-sized units)
are standard.

> The use of standard software considerably reduces the work of the operator.
Using optional teach-in software, even the most complicated operating
sequences can be programmed.

> The extreme reliability and durability of ENGEL ROBOTS can be attributed
to the consistent use of high-quality materials and components and to more
than 20 years experience in the development and construction of robots.
ENGEL ROBOTS.
It's the details that count: rotary axes.

01 Cable and hose track system for rotary axes

01 02 ABC-rotary axes, completely servo driven
03 ABC-rotary axes combination with pneumatic
C-axis and servo-driven A- and B-axes

8
02 03

B-axis

B-axis

C-axis

C-axis
A-axis A-axis

Ro ta r y a x es
T h e s tan dard e q ui p me nt of a n ENG EL ER C ro bo t or for special rotational movements directly at the mold
con s is ts of a p ne uma t i c sw i v e l l i ng a xi s ( C - a xi s) fo r and/or downstream peripheral unit, Engel can offer the
the swing-out movement of the molded part from the perfect servo/pneumatic combination of rotary axes for
demolding operation, to its placement on a conveyor e v e ry a ppl i c a ti o n.
belt o r in a c ol l e c t i ng b ox. For more c om pl e x A c a bl e a nd ho se tra c k pa c k a g e i s a l so avai l ab l e – as
s equ en ces of mov e me nt , Enge l offe rs a di v e rsi ty o f an optional accessory – for each rotary axis. This serves
combin atio ns of p ne uma t i c a nd se rv o-d r i v e n ro ta ry to g ui de the e l e c tri c c a bl e s a nd a i r ho se s f ro m t h e
axes. A three-axis ERC linear robot can, for example, l o w e r e dg e o f the v e rti c a l a rm to the g rip p er h ead .
be u pgr ade d t o a si x-a xi s rob ot t hrough the a ddi ti o n This track package is particularly advantageous in the
o f A, B, an d C rot a ry a xe s. No ma t t e r w he the r the case of multi-axial robots, as it ensures that the cables
requ iremen t i s for sp a c e -sa v i ng, gri d -p atte r n a nd ho se s fo r the di ffe re nt a xe s c a nno t r u b ag ai n s t ,
placemen t on a c onv e y or b e l t or i n t ra y s o r bo xe s, tra p o r i m pe de o ne a no the r.
Insert-placing and parts-removal: the Engel Grip Tools system

01 02

9
03

Engel builds gripper heads for every requirement, from

the standardized parts-removal head based on Engel's
modular GRIP TOOLS system to complex, application-
specific insert-placing, parts-removal and transfer heads.

01
For standard part handling applications, Engel has developed
the modular GRIP TOOLS system for such components as
suction heads, grippers, sensors, quick-change systems and
pneumatic accessories. This modular system enables the
u s e r t o f a b r i c a t e h i s o w n g r i p p e r h e a d s w i t h o u t d i ff i c u l t y.
T h e G R I P T O O L S o rd e r c a t a l o g u e i s a v a i l a b l e b o t h a s a C D
and on-line on the Internet.

02 / 03
Even in cases involving complex part geometries and difficult
handling tasks, Engel designs, constructs and optimizes
insert-placing and parts-removal heads – complete, product-
s p e c i f i c s o l u t i o n s f ro m j u s t o n e s u p p l i e r.
ENGEL ROBOTS.
Integrated controls RC 100 and RC 511.

Rob ot control system EN GEL RC 100

- The Engel robot control system and machine control
system are fully integrated and feature a common
control panel for the injection molding machine, the
robot and the peripherals. The control cabinet is an
integral part of the machine dimensions, thus saving
considerable floor space.
- All settings for the machine, the robot and the
peripherals can be stored on just one diskette.
- The Engel menu programs for standard operating
sequences make special programming skills
unnecessary.
- The additional ”Quick Pos” function enables the
operator to move the robot rapidly to a pre-
determined position.
10
- ”Quickset Single” and ”Quickset All” store the actual
position of one or several axes, thus considerably
reducing the time required for set-up.
- The ”Reposition” function permits continuation of
the automatic cycle after an interruption, whatever
the situation.
- The ”Teach-in” function represents a convenient and
flexible method of programming special operating
sequences. The sequences are performed manually
and are stored step by step, also allowing for
integration of the menu programs.
- The RC 100 control system is able to control up to
6 servo-driven axes at high speed and with absolute
precision. The three-dimensional path control
package offers linear, circular and spline interpolation
for the simulation of all axes.
- The ”Off Limit” software package affords fully
integrated safety as standard. W ith its 24 ”guards”
watching over the entire working envelope of the
robot, it prevents collisions caused by wrong settings
and adjustments. All axial movements are
automatically monitored according to setpoint input,
thus reliably protecting the mold, the machine, the
01 02 robot and the peripherals against all possible
damage.

01 Manual operating unit HBG3

02 Manual operating unit HBG2
Engel quality for all injection molding machines.

01 02

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03 04

E NG E L E RC R OB OT S o n all make s
o f i n j e c ti o n moldin g mach in e.
Engel linear robots can generally be used on all makes
and types of injection molding machine.
For such applications, Engel offers its ERC ROBOTS
with the RC 511 stand-alone control, enabling the robots
to communicate with the machines via either the 01 ENGEL ERC on KraussMaffei
EUROMAP 12 or SPI interfaces. The RC 511 is a high- 02 ENGEL ERC on Ferromatic Milacron
performance control system, having the same range of 03 ENGEL ERC on Nestal 1500
functions as Engel's standard RC 100 control system. 04 ENGEL ERC on Battenfeld BA 350
ENGEL ROBOTS.
Basic automation: ER-A sprue removal robots.

S p r u e remo val robot s Sp r ue rem ov al rob ot

E R - A 3/A, ER-A Ty p e 5, 6, 7
E R - A 4/A Ver sion A or B
Sprue removal and separation are an integral part Both versions of this sprue removal robot (A + B)
of th e aut oma t i on p roc e ss. Enge l offe rs sprue a re o pe ra te d v i a the m a c hi ne c o ntrol s ys t em .
removal robots for injection molding machines with Various sequence programs can be selected from
clampin g forc e s ra ngi ng from 28 t o 250 U S to ns. the ro bo t' s c o m pre he nsi v e m e nu so f t w are.
The control systems for these sprue removal robots B o th v e rsi o ns a re e qui ppe d a s sta nd ard w i t h a
are likew i se i nt e gra t e d i n t he ma c hi ne c o ntro l ba c k pre ssure m o ni to ri ng de v i c e i n t h e g r i p p er
s ys tems , t hus offe ri ng t he sa me a d v anta g e s a s w hi c h e na bl e s the ro bo t to re c o g ni z e t h e p ar t .
those featured by all other series of Engel robots.

12

T h e robo ts a re st urd i l y b ui l t a nd fe a t ure a n e xtre m e l y The A version has been designed for retrofit applications,
compact desi gn, a s t he y c a n ut i l i z e t he a dv a nta g e s e l i m i na ti ng the ne e d fo r the subse que n t i n s t al l at i o n o f
aff o rded by t he t i e b a rl e ss i nj e c t i on mol d i ng m a c hi ne . a sprue di sc ha rg e c hute i n the sa fe ty gu ard .
As th ere is no ne e d t o ne got i a t e a ny up p e r ti e ba rs, Afte r re m o v a l o f the sprue , the v e rti c a l ax i s s w i n g s
a much shorter vertical stroke is possible in comparison upw a rd thro ug h a n a ng l e o f 9 0° a nd o p er at es as a
with alter native machine models equipped with tiebars. ho ri z o nta l a xi s, e na bl i ng the ro bo t to d i s ch ar g e t h e
T h e ben ef it i s a muc h fa st e r sp rue re mo v a l ti m e . sprue o utsi de o f the sa fe ty g ua rd.
T h e robo t it se l f i s mount e d on t he st a t i o na ry pl a te n. The B version has been designed for integration in the
The safety cover of the machine protects the operating safety guards of new machines within the 28 to 250 US
s pace o f the rob ot . to ns ra ng e .
The sprue discharge position is likewise an integral part T he ro bo t di sc ha rg e s the sprue i nto th e ch u t e o n t h e
o f th e machi ne gua rd i ng. A s a hi gh-sp e e d v e rsi o n o f back of the machine by performing a rotary movement
th e ver tical a xi s i s now a l so a v a i l a b l e , t h e v e ry fa ste st a ro und the v e rti c a l a xi s o f i ts suppo rt.
demo ldin g t i me s c a n b e a c hi e v e d .
TLi robots:
fully benefiting from the tiebarless machine concept.

In te g r a te d h an dlin g robot s for

t i e ba r l e ss in ject io n moldin g
m a c h i n e s: E R -TL i
Fo r s tan dard ” p i c k a nd p l a c e ” a p p l i c a t i ons on
En g el tiebar les s ma c hi ne s w i t hi n t he 28 t o 66 0
US tons range, the Engel ER-TLi robots represent
a low- cos t mea ns of a ut oma t i on.

13

The ER- TLi robot is used in cases where molded parts The Z-axis of the ER- TLi is freely positional by means
c a nn o t be g r avity-d i sc ha rge d from t he mol d b ec a use o f a se rv o m o to r, w hi c h m e a ns tha t the m o l de d p ar t s
they are still hot and easily damaged, or in cases where can be deposited on the conveyor belt in rows. Separate
t he par ts are to be p a c ke d d i re c t l y a t t he ma c h i ne . po si ti o ni ng o f the pa rts a c c o rdi ng to qua l i ty c r i t er i a i s
Normally, the ER- TLi robot is mounted on the stationary a l so po ssi bl e . T he ro bo t c o ntro l sy ste m i s c om p l et el y
p l a t en an d th e part s a re d e p osi t e d on a n i nt e gra te d i nte g ra te d i n the m a c hi ne ' s c o ntro l sy ste m , a l l o w i n g
conveyor belt located within the safety guard. In order fo r e a se o f se t- up a nd a dj ustm e nt.
t o p rovide ready ac c e ss t o t he mol d , t he p osi t i o n o f The robot settings are stored together with the machine
t he con veyo r belt c a n b e shi ft e d si d e w a y s i n t he se tti ng s o n the sa m e di sk e tte . B y re a so n o f th e
m ach in e directio n . The sy st e m c a n a l so b e op t i o na l l y integrated design of robot and machine, the distances
equipped with a step-by-step reversing mechanism for travelled by the robot, and therefore also the demolding
clearing the belt when it is full. For multi-color machines ti m e s, a re e xtre m e l y sho rt. M o re o v e r, suc h c ycl e t i m e
equipped with vertical injection units, the ER- TLi robot re duc i ng func ti o ns a s ” Adv a nc e Re spo nse ” a n d / o r
c a n als o be mou n t e d on t he mov i ng p l a t e n. ” Pa ra l l e l Ej e c ti o n” c a n a l so be use d to furthe r s p eed
up the de m o l di ng ti m e .
ENGEL ROBOTS.
Highest speeds for the thinnest lightweights.

14

H i g h - sp eed part s -removal rob ots:

E RS ( S p eedy)
- C u r ren t p rod uc t d e v e l op me nt ge ne ral l y re v e a l s a - The ERS (Speedy) series is specifically distinguished
mar ked t re nd t ow a rd s i nc re a si ngl y t hi nne r a nd by the fo l l o w i ng pe rfo rm a nc e fe a tu res :
lig h ter p a rt s – a nd i nc re a si ngl y fa st e r pro duc ti o n > Suitable for total cycle times of less than 5 sec.
times . > M i ni m um de m o l di ng ti m e i s 0 . 3 s ec.
- T h e an sw e r t o t hi s t re nd – i n t e rms o f a uto m a ti o n > Li ne a r spe e ds o f up to 8 m / s a re p o s s i b l e.
– is th e ERS ( S p e e d y ) . Thi s hi gh-sp ee d pa rts- > M a xi m um a c c e l e ra ti o n o f 1 5 0 m / s 2 .
remo val rob ot ha s b e e n d e si gne d for the ha ndl i ng T ha t' s a ppro xi m a te l y 1 5 ti m e s fa s t er t h an
o f th in - w a l l or t hi n-se c t i on p a rt s, a nd fo r use i n a c c e l e ra ti o n due to g ra v i ty !
con ju n ct i on w i t h fa st -c y c l i ng i nj e c t i o n m o l di ng
mach in e s. - T he ” Spe e dy ” hi g h- spe e d pa rts- re m o val ro b o t can
- T h e ch a ra c t e ri st i c w orki ng p ri nc i p l e o f the ERS be readily combined with such Engel peripherals as
(Speedy) c onsi st s i n t he l a t e ra l re mo v a l o f pa rts the Engel Trayserver, for example, converting a fast-
from the mold by means of a high-speed linear axis. c y c l i ng i nj e c ti o n m o l di ng m a c hi ne in t o a f u l l y
T h is ax i s c a n a l so b e c omb i ne d w i t h a ro ta ry o r a uto m a te d hi g h- spe e d pro duc ti o n cel l .
s wivel a xe s.
T h e h ighl y d y na mi c se rv o mot or a nd the use o f
h igh - s tre ngt h, l ow -w e i ght ma t e ri a l s to g e the r
g u ar an t e e t he v e ry short e st d e mol d i ng ti m e s.
Engel logistic modules for the controlled,
systematic storage of molded parts.

15

01

04
03

02

01 De-stacking unit A-B with empty trays

02 Lifting units
03 Tray loading position for robot
04 Stacking unit A-B with full trays

Tr a y se r v e r : E T S 1
- E n gel E TS Tr ay se rv e rs i d e a l l y c omp l e me nt the - O pe ra ti o n o f the Eng e l Tra y se rv e r i s fa c i l i t at ed b y
in jection moldi ng ma c hi ne a nd t he rob ot , as the a n i nte g ra te d sta nd- a l o ne c o ntro l w o rk i ng i n
res u ltin g co mb i na t i on i s a ful l y a ut oma t e d c o nj unc ti o n w i th a l i g ht si g na l i ndi c a to r p an el .
produ ction cel l . - The Trayserver is the logical solution to the problem
- E n gel Tr ays er v e rs a re use d i n c a se s w he re the of producing high-quality injection molded parts on
molded parts have to be protected in transit and/or a n una tte nde d m a c hi ne .
have to be stored in the right position in readiness
f or au tomatic d ow nst re a m p roc e ssi ng. More o v e r,
they enable the injection molding machine and the
ro bo t to wo r k e nt i re l y una t t e nd e d ; a n op e ra to r i s
requ ired merel y t o re mov e t he fi l l e d t ra y s and
replen is h th e Tra y se rv e r w i t h e mp t y t ra y s.
- Engel Trayservers have been developed for use with
s tan dard tr ay si z e s, e .g. 60 x 400 mm, a nd c a n
each be operated with 2 stacking and de-stacking
u n its . Bes ides p l a st i c t ra y s, t he Enge l Tra y se rv e rs
can also be used in conjunction with plastic boxes
tr an s po r ted o n fl a t or st ud d e d b e l t s.
ENGEL ROBOTS.
Engel automation for efficient, high-quality logistics.

C o u p le d , syn c h ron i z e d oper at io n o f 3 machines.

Fully automated production cell for the manufacture of three-part air intake
manifolds. The operation of the three injection molding machines are synchronized
so as to ensure the production and downstream welding of parts which have
the same previous history.
Three ENGEL ERC 83/1-E
linear robots with special
supports mounted at
right angles to standard
support position.

Lifting unit for transferring

individual molded parts to the
collecting conveyor.
16
The collecting conveyor
transports the parts to
the welding station.

Multi-unit injection molding set-

up comprising of two ENGEL
CLASSIC 5550 / 660 US and one
ENGEL CLASSIC 3550 / 610 US
injection molding machines.
Minimum floor space requirement
was the main design criterion.
The conveyor belts for the
molded parts are each arranged
above the clamp units.

A u t o m a ti on of c om p l e x a s sembling pro cesses.

Pro du ction l i ne for t he ma nufa c t ure o f c a r c a bl e c o ndui ts w i th fa ste ni ng c l i ps.

ENGEL ERC 65/1-C

Linear robot for the
horizontal transfer of
inserts into the machine.

Gripper head for insertion of

clips into mold and removal of
cable conduits after molding.
The parts are tested by the
gripper's integrated quality
control device and then
placed in storage boxes.

The plastic clips are fed from the

bulk container to the separating
station via a vibroconveyor.
They are then positioned by an
Engel linear robot at distances
corresponding to the distances
between the mold cavities, in
readiness for transfer by the
machine robot to the mold .
Automation of a vertical machine.
Fully automatic production cell for the manufacture of gearshift levers for automatic gearboxes.
The inserts are first transported by the robot to the pre-heating station and from there, correctly
oriented, into the mold cavities. Following encapsulation, the finished parts are removed from the
mold in pairs and deposited on a conveyor belt with collecting zone.
Injection molding machine
ENGEL INSER T 500V / 90 with
vertical rotary table clamping
unit permitting insertion and
removal in parallel with the
injection molding cycle.

ENGEL ERC 53/1-E Linear robot,

gantry version. The robot's
control system co-ordinates
the operating sequence of the
entire production cell.
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Discharge conveyor belt

for the finished parts.

The parts are deposited

in pairs in the collecting
zone of the conveyor.

Safety area for

machine and robot.

Automation of CNC machine tool

Flex ible au to ma t i on of a CNC l a t he w i t h a n EN G EL ER C 8 3 / 1 - C l i ne a r ro bo t
e qu ipped with a n RC 511 st a nd -a l one c ont ro l .
With one of its grippers, the robot
removes a metal blank from a
pallet and transfers it to a length
measuring station

The double gripper removes the

turned part from the chuck of the
lathe and, after performing a
rapid axial rotation, inserts the
blank into the chuck

Stacking station with integrated

pallet changer. The finish-
machined parts are stacked on
the pallet by means of a robot