In these challenging economic times, plastics molders are
searching for new automation paths. This search is leading
to alternatives to buying new robots.
Rebuild Existing Robots or Buy Fully Rebuilt Robots
Two popular options involve either rebuilding existing robots, or buying fully rebuilt robots from a
qualified manufacturer.
Rebuilt robots:
- reduce the risk of buying used robots ‘as-is’ that may need service
- are usually half the cost of new robots, with a full service warranty provided.
Rebuilding allows molders to:
- improve motion controls with either SERVO or INDRO controls
- gain better speed, torque and repeatability
Controls based on established vendors such as Allen-Bradley or GE Fanuc have an inherent
advantage of easy "Do-It-Yourself" (DIY) service, with PLC parts & training available across
North America.
Such simple PLC controls provide 100% ‘debug transparency’, so a trained electrician can
see all details of operation, including:
- program code, every bit & byte of database, and complete processor details
- major advantage over embedded and custom robot controls based on proprietary designs and
specialized parts.
With popular software such as Allen-Bradley’s RS-Logix, engineers & technicians can
troubleshoot with familiar software used across many industries. This ‘DIY’ common environment
allows robot repairs to be performed by in-house workers, at lower cost and without additional
outside service travel time.
Advantages of Rebuilding Gantry Robots
The major advantage of Rebuilding versus buying new is the large capital cost savings. A rebuilt
robot can provide the same advanced controls & software for about half the cost of a new robot.
Rebuilt robots with similar controls provide:
Faster speeds (lower in-mold time), thus increasing parts molded
Continued use of existing spare parts, alleviating the cost of new spare parts
Familiar controls hardware, eliminating any learning curve for maintenance technicians
Minimal software training due to familiarity
Improved reliability, increasing machine uptime and parts molded per year
Up-to-date software and operator interfaces, reducing error recovery and product
change-over time
Refurbished robots:
There is also an advantage to partial rebuilds (Refurbishing). are from
20% to 30% LESS than new. They are completely remanufactured, with the old control replaced
by a state-of-the-art controller, making them very similar to new robots. The only difference is
that large, durable structural components (e.g. steel beams & channels and aluminum frames &
tubes) are re-used. Refurbishing is a cost-effective, environmentally sound option.
Robot Re-Deployment Summary
As an injection molder competing with off-shore manufacturers, you need to continuously reduce
production costs to insure profitability. One of the best ways of meeting this goal is to automate
parts-handling at the mold machine. For small to medium sized molders who are budget-driven,
rebuilding current robots is a good alternative to buying new robots. Like ‘certified’ used cars,
rebuilt robots provide good cost savings at one third of new pricing, while insuring adequate
reliability & performance.
Re-building older pneumatic or electric robots, and converting them with servo motors increases
robot speed by 150-300%, reduces mold change-over time, improves machine up-time, and
increases positioning accuracy. All of these improvements allow injection molders to deliver
product faster while reducing costs. Such performance improvements can be obtained at 50% of
the cost of new robots, while extending robot lifetime by several to ten years. Unlike used robots
purchased at auction, a fully rebuilt robot comes with a 1-2 year full warranty, significantly
reducing your investment risks.
Plastics molders have several options besides popular pneumatic and high-end servo robots.
From Hybrid robots to INDRO and Double-Speed INDRO robots, frequency drives can provide
servo-like performance with somewhat lower speed & payload, but at much less cost. And
SIMPLE PLC-based rectilinear robots can perform many of the simple molding jobs without the
cost of multiple servo motors or non-standard proprietary controls.
Easy-to-use SIMPLE PLC-based robots allow small and mid-size molders a cost-effective way to
automate without the complexity of PC or embedded controls, and without the burden of
programming languages. And simple Do-It-Yourself PLC controls allow molders to perform
debug & service in-house, without waiting to pay high prices for call-in service engineers. If you’
re a molder looking to improve automation on a set budget, consider the cost savings and
reliability of rebuilt and refurbished robots. Money saved redeploying existing robots can be
used for other important projects, or to improve your profitability.
searching for new automation paths. This search is leading
to alternatives to buying new robots.
Rebuild Existing Robots or Buy Fully Rebuilt Robots
Two popular options involve either rebuilding existing robots, or buying fully rebuilt robots from a
qualified manufacturer.
Rebuilt robots:
- reduce the risk of buying used robots ‘as-is’ that may need service
- are usually half the cost of new robots, with a full service warranty provided.
Rebuilding allows molders to:
- improve motion controls with either SERVO or INDRO controls
- gain better speed, torque and repeatability
Controls based on established vendors such as Allen-Bradley or GE Fanuc have an inherent
advantage of easy "Do-It-Yourself" (DIY) service, with PLC parts & training available across
North America.
Such simple PLC controls provide 100% ‘debug transparency’, so a trained electrician can
see all details of operation, including:
- program code, every bit & byte of database, and complete processor details
- major advantage over embedded and custom robot controls based on proprietary designs and
specialized parts.
With popular software such as Allen-Bradley’s RS-Logix, engineers & technicians can
troubleshoot with familiar software used across many industries. This ‘DIY’ common environment
allows robot repairs to be performed by in-house workers, at lower cost and without additional
outside service travel time.
Advantages of Rebuilding Gantry Robots
The major advantage of Rebuilding versus buying new is the large capital cost savings. A rebuilt
robot can provide the same advanced controls & software for about half the cost of a new robot.
Rebuilt robots with similar controls provide:
Faster speeds (lower in-mold time), thus increasing parts molded
Continued use of existing spare parts, alleviating the cost of new spare parts
Familiar controls hardware, eliminating any learning curve for maintenance technicians
Minimal software training due to familiarity
Improved reliability, increasing machine uptime and parts molded per year
Up-to-date software and operator interfaces, reducing error recovery and product
change-over time
Refurbished robots:
There is also an advantage to partial rebuilds (Refurbishing). are from
20% to 30% LESS than new. They are completely remanufactured, with the old control replaced
by a state-of-the-art controller, making them very similar to new robots. The only difference is
that large, durable structural components (e.g. steel beams & channels and aluminum frames &
tubes) are re-used. Refurbishing is a cost-effective, environmentally sound option.
Robot Re-Deployment Summary
As an injection molder competing with off-shore manufacturers, you need to continuously reduce
production costs to insure profitability. One of the best ways of meeting this goal is to automate
parts-handling at the mold machine. For small to medium sized molders who are budget-driven,
rebuilding current robots is a good alternative to buying new robots. Like ‘certified’ used cars,
rebuilt robots provide good cost savings at one third of new pricing, while insuring adequate
reliability & performance.
Re-building older pneumatic or electric robots, and converting them with servo motors increases
robot speed by 150-300%, reduces mold change-over time, improves machine up-time, and
increases positioning accuracy. All of these improvements allow injection molders to deliver
product faster while reducing costs. Such performance improvements can be obtained at 50% of
the cost of new robots, while extending robot lifetime by several to ten years. Unlike used robots
purchased at auction, a fully rebuilt robot comes with a 1-2 year full warranty, significantly
reducing your investment risks.
Plastics molders have several options besides popular pneumatic and high-end servo robots.
From Hybrid robots to INDRO and Double-Speed INDRO robots, frequency drives can provide
servo-like performance with somewhat lower speed & payload, but at much less cost. And
SIMPLE PLC-based rectilinear robots can perform many of the simple molding jobs without the
cost of multiple servo motors or non-standard proprietary controls.
Easy-to-use SIMPLE PLC-based robots allow small and mid-size molders a cost-effective way to
automate without the complexity of PC or embedded controls, and without the burden of
programming languages. And simple Do-It-Yourself PLC controls allow molders to perform
debug & service in-house, without waiting to pay high prices for call-in service engineers. If you’
re a molder looking to improve automation on a set budget, consider the cost savings and
reliability of rebuilt and refurbished robots. Money saved redeploying existing robots can be
used for other important projects, or to improve your profitability.
| RE-DEPLOYING ROBOTS FOR PLASTICS INJECTION MOLDERS |
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