SUMCAB dresspack systems for extraction robots for injection moulding machines at the Röchling Automotive factory in Wackersdorf ensure process reliability and facilitate short cycle times. This is made possible by the high wear resistance of our products, which are coordinated with the motion sequences of the robots. Rudolf Lietz, Group Leader of Maintenance within the factory, is also impressed with our ability as specialists to develop solutions and the commitment of our technicians.

The articulated robots perform complicated motion sequences, sometime at very high speeds. In addition, the highly complex grippers have to work in extremely restricted spaces. This used to make the dresspack systems for the robots’ media supplies susceptible to wear and tear, resulting in frequent injection plant outages.

The fact that the machinery is significantly more reliable today is due entirely to the dresspack systems from SUMCAB Specialcable GmbH. In early 2016, a member of our sales team travelled to the factory from Pfedelbach in Baden Württemberg to demonstrate retraction systems for portable teach device cables. During the meeting, one of the extraction robots deployed next to an injection moulding machine in the production area developed a power supply issue. Because this robot goes through a series of highly complex movements, cable breakages at the manual axis have caused multiple power supply issues in the past. The SUMCAB representative informed his hosts that the SUMCAB portfolio includes specific solutions for precisely such problems.

A SUMCAB service engineer went along to the following meeting at the factory and was able to offer a concrete proposal for how to achieve a significant improvement in the situation. The robot at injection moulding machine 18 was subsequently fitted with one of our dresspack systems.

Rudolf Lietz, Group Leader of Maintenance at the Wackersdorf works recalls: “We swapped the existing dresspack system on the pilot plant with a SUMCAB product, which enabled us to rectify the problem. The SUMCAB dresspack system follows the robot's movement without a problem. Since then, the machine has operated to our full satisfaction. We were so impressed by this that we're now successively upgrading all of the injection plant throughout the factory. Our experiences with the dresspack systems of other manufacturers were bad; they were simply too vulnerable to wear”.

SUMCAB not only supplies the Wackersdorf works with the dresspack systems but also installs them on the robots and then optimises them under live production conditions. The SUMCAB engineers then return to the factory about a month later to inspect the dresspack system for any signs of wear. They also make sure that it is configured correctly and make any slight adjustments that may be needed.

SUMCAB's special cable retraction system enables a streamlined routing of the dresspack system on the robot. Praising the system, Rudolf Lietz says that: “it's the optimum low-wear media routing system, especially for complex robot applications. This simple but effective technology enables a variable length power supply to the robot. The dresspack systems are always under the correct tension throughout every movement, which prevents looping, and reduces wear and tear. The SUMCAB folks have put a lot of thought into it and it's evident that a lot of experience has gone into this solution”.

The wear resistance of the dresspack systems also contributes to an increase in injection moulding plant productivity. The well-guided movement sequences makes it possible to shorten the cycle times. “We can now operate at higher speeds”, says the maintenance expert, “because we know that the dresspack systems enable this without anything failing either on the robot or on the periphery”.

He also sees the rapid, plug-and-play swap-out feature of our dresspack systems as a major benefit: Röchling Automotive Germany’s in-house maintenance team can do it themselves. According Lietz, SUMCAB’s plug connections are much easier to use than those of other manufacturers, who also offer plug-and-play solutions, which, he says, saves time and reduces production downtime.

By October 2017, five robots at the Wackersdorf works had already been upgraded. The plan is to fit the robots at the other injection moulding stations with SUMCAB dresspack systems to increase their reliability. Moreover, the decision to use SUMCAB products as standard also simplifies the spares holding provision.