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Custom Fanuc robot automatic feeding system for injection molding machines. Eliminates manual loading, reduces cycle time variation by 30‑50%, 24/7 operation, custom end‑effectors. Boosts OEE, cuts scrap up to 80%. Payback 6‑12 months. Integrates with any injection molder.
Fanuc Robot Automatic Feeding System for Injection Molding Machines
The Automated feeding solution for Injection molding machine by Fanuc industrial robot is an automated solution providing the utmost in mechanised feeding; therefore, the need for manual handling of material flow on a plastic injection machine are completely eliminated. The Automated solution provides the fastest method possible to load inserts, pre-forms or raw material into the injection moulding machine while producing minimal variations in speed or cycle times and immediate savings in labour cost leading to a significant improvement in overall equipment effectiveness (OEE).
The appliance works with all types of injection molding machinery (either vertical or horizontal) and offers the capability to process multiple geometry types. The automated arm provides exactly the same part orientation and timing every time, resulting in reduced idle machine time due to human errors or other types of defects. With its ability to operate unattended 24 hours a day/7 days a week, the robot also provides consistent cycle times and allows skilled workers to devote their efforts to quality control and improving the molding process. Among other things, the robot will provide a reduction in cycle time variability of 30 percent – 50 percent, and an 80 percent reduction in labor cost for the labor involved in handling parts from the time they exit the machine until they enter into the delivery container.
Standard delivery: 60-90 days | Fanuc robot integrated | Custom end‑effectors
What is a Robot Automatic Feeding System for Injection Machine?
An automated system for feeding an injection molding Machine using industrial robots is referred to as an “Automated Material Handling Cell”. This type of system uses an industrial Robot (i.e. Fanuc, KUKA or ABB) to automatically load inserts, pre-forms or raw materials into an injection molding machine, where as, when done manually, loading may be subject to operator fatigue, inconsistent placement of inserts, and cycle time variability.
The robotic system ensures that the insert(s) will be positioned accurately every time, will have consistent timing for each cycle of the Robot, and can run with continuous operation. The robotic system will consist of the following; (1) robot arm with custom end-effector (gripper), (2) part feeder (vibratory bowl or tray), (3) safety guarding, (4) PLC integration with the injection molding machine.
Examples of applications for the robotic system are for insert molding (utilizing metal inserts, magnets, or threaded bushings), over-molding or automatic feeding of raw materials. The robotic system may also unload finished products, thereby creating a complete automated cell for the injection molding process.
Since these types of systems are typically not standard off-the-shelf solutions, we customize the end effector, part feeder and Robot programming to your specific part geometry, mold layout and cycle time.
High speed, precision, and reliability – proven in harsh industrial environments.
Eliminates cycle time variations, reduces machine idle time.
Maximizes injection machine utilization, improves OEE.
Designed for your specific inserts (metal, plastic, magnet, label).
System Features & Integration
مشخصات فنی
| Robot model (standard) | Fanuc LR Mate 200iD or R‑2000iC (others available) |
|---|---|
| Payload capacity | Up to 7kg (LR Mate) / up to 165kg (R‑2000iC), depending on robot |
| Reach | Up to 717mm (LR Mate) / up to 2,650mm (R‑2000iC) |
| Repeatability | ±0.02mm – ±0.05mm (robot model dependent) |
| سیستم تغذیه | Vibratory bowl, tray stacker, or conveyor (custom per part) |
| End‑effector type | Pneumatic or servo gripper, vacuum cup, magnetic, or custom |
| Integration signals | Digital I/O or Ethernet/IP to injection molding machine PLC– |
| Safety features | Safety fence with interlock, light curtains (optional), emergency stop– |
| سیستم کنترل | Fanuc robot controller + integration PLC (optional)– |
| منبع تغذیه | 380V ±10% 50Hz (robot) | 220V for feeder | Compressed air 0.6MPa– |
مزایای فنی اصلی
Eliminates cycle time variation
Manual loading causes injection molding machine idle time due to operator fatigue or inconsistent placement. The robot always loads with the same timing (e.g., every 30 seconds), reducing cycle time variation by 30‑50% and increasing machine throughput.
24/7 unattended production
With the robot feeding system, the injection molding machine can run continuously during breaks, shift changes, and overnight. This boosts OEE from typically 60‑70% to over 85%, directly increasing daily output without additional machines.
Precise insert placement reduces rejects
The robot’s repeatability (±0.05mm) ensures that metal inserts or pre‑forms are placed exactly in the mold cavity every cycle. This eliminates misalignment defects (cracked inserts, flash, or incomplete filling), reducing scrap rate by up to 80%.
Quick changeover for multiple part types
The end‑effector and feeder bowl can be swapped in under 15 minutes. Recipe‑based robot programs (via HMI) allow changeover between different insert sizes without reprogramming, increasing production flexibility.
Customer Success Story – Automotive Insert Molder
A first-tier automotive supplier put brass inserts into the injection molding machine manually for making dashboard parts. At times, cycle times were inconsistent (between 45 and 70 seconds), which often resulted in the company scrapping 5% of the parts because of improperly positioned inserts. Benlong installed a Fanuc robotic automated feeding device and custom gripper with vibratory bowl to feed brass inserts into the machine. Within 6 months of usage, this installation of automation resulted in the following:
After 10 months the customer did not need to pay for using the system anymore; then at that time they could have it fully for free and operate without lights for weekend production.
کاربردها و ادغام
Custom Engineering & Delivery
Request a Custom Robot Feeding System Quote
Please provide us with a copy of your inserts, your injection moulding machine model and your intended cycle time; we will then create a custom Fanuc robot feeding system for you, which will include custom designed end-effectors and feeders, and will also include a full ROI analysis.
واتساپ: +86 150 5837 0007 | ایمیل: xsb@benlongkj.cn | پشتیبانی انگلیسی و چینی
Why Choose Benlong for Robot Feeding Automation?
- 15+ years integrating robotic feeding systems for injection molding
- Certified Fanuc system integrator – full programming and support
- Custom end‑effector design (grippers, vacuum, magnetic)
- Seamless PLC integration with any injection molding machine (Arburg, Engel, Haitian, etc.)
- خدمات جهانی و پشتیبانی قطعات یدکی
Typical Custom System Includes
Robot: Fanuc (Payload: varies by model) – End Effector (Pneumatic/Servo) – Part Feeder (Vibratory Bowl or Tray) – Safety Enclosure and Interlock – Robot Controller + HMI – Integration PLC (Optional) – I/O interface to injection moulding machine – Installation and Training – 1st Year Warranty
سوالات متداول
Absolutely. Our firm has the capabilities of producing a multi-gripping end effector capable of grasping two different sized threaded inserts and placing them in separate cavities. The robot program can also be sequenced for the alternate loading of different sized threaded inserts.
Of Course. A single robot can also be programmed to take off the molded parts and load them on a tray or conveyor. In addition, this set-up results in a totally automatic molding cell (insert load + part unload).
The feeder bowl has orientation sensors and a reject gate, so any inserts that are upside down or damaged get automatically rejected by the feeder bowl. In addition, there are part-present sensors on the gripper of the robot. These part-present sensors also prevent the robot from completing the loading cycle if it does not detect any parts during this cycle. If the robot detects zero parts during a preset amount of cycles, it will alarm.
A single injection molding machine that operates three shifts generally achieves a payback period of six to twelve months by reducing labour costs due to replacing two to three operators per shift and increasing OEE through a reduction in idle time.
Absolutely. You can connect to the machine via basic I/O signals such as ready, mold open or mold closed. In addition, you can upgrade the machine with the addition of a small PLC that interfaces with the existing systems. There is no need to make major adjustments to the machine.
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