Software and simulation

We’ve also been told that Industry 4.0 will see different machines working together as a unit. Increasingly, processors are discovering that they can, in fact, improve productivity and make added- value parts when robots collaborate not only with IMMs but other equipment as well. These include customized, multifunctional end-of-arm tooling, insert feeders and positioning systems, and post-mold inspection, assembly and packaging equipment that yield specific solutions in: • Control… vision; presence/absence of components; electrical continuity • Parts handling… shuttle tables; vertical stackers • Traceability… marking; labeling; separation by cavity • Assembly… closing; clipping; screwing; welding • Cutting… gate vestige removal; flash removal; routing These systems can get quite complex. For instance, a molder making kitchen utensils created a cell that involves two molding machines, three 3-axis robots, an insert loading station and shuttle table. In operation, a small 3-axis robot stages six metal utensil-handle inserts for pick-up by a larger robot on one of the two IMMs. That machine molds a TPE grip onto the handles and then the robot returns to remove the molded handles and place six more inserts. The molded handles are then placed in a fixture on the shuttle table that moves them over to the second molding machine. The large robot on that machine picks them up and places them into the second mold, where a stiffer, heat-resistant material forms the working end on the utensil. The second robot removes the finished parts, places them on a conveyor to a packing area and the cycles repeat. That’s integration. Collaboration Drives Industry Forward Because Industry 4.0 is bigger than the plastics industry alone, Sepro is working with other businesses and institutions to share knowledge, resources and perspective. For instance, Sepro is collaborating with the Robotics Institute at Carnegie Mellon University in Pittsburgh, PA, to develop the next generation of robot and injection-molding machine controls. The project is still in the development phase, but it is likely that the new controls will feature elements like ‘agile’ ergonomics, similar to tablets, the ability to ‘learn by doing,’ 3D simulation to make programming easier, extensive customization, and ‘apps’ to facilitate routine functions like maintenance and troubleshooting. However, collaboration cannot be confined within one industry. So, Renaudeau is actively involved in developing innovative management practices with Audencia Business School in Nantes, one of the top business schools in France and in Europe. The school has 3470 students from over 80 countries in its bachelors, international and specialized masters, MBA, doctoral and executive education programs. Sepro CEO Jean-Michel Renaudeau calls this “crossing the border.” When people and companies share resources, he says, they develop a more global view. They gain information and understanding that allows them to become stronger quicker. He points to his own company as an example of how these kinds of connections ultimately benefit plastics injection molders. “How does a relatively small company like Sepro, in the middle of nowhere in western France, become a global leader in robotics and automation,” he asks? “Industry 4.0 is not just about technology that allows machines to communicate. That’s a part of it, but more importantly it is about people and companies multiplying our own capabilities through collaboration and a shared vision of the future. Why else are auto companies like Ford actively working with service companies like Uber?” This vision of Industry 4.0, what Renaudeau refers to as “the commons sense view,” and Sepro’s commitment to it, has allowed us has been able to make big things happen in a short period of time. It can help plastic injection molders make great strides too. They will certainly discover that, thanks to today’s robots and evolving technology, the future is wide open.