Plastic Injection Automation Cell with PCB and Pin Handling

Client Needs & Project Goals

The client required a fully automated solution for inserting pins and PCBs into a plastic injection tool, followed by inline inspection and sorting. Key requirements included:

automated feeding, punching, and lubrication of pin stripe,
precise insertion of pins into plastic injection tool
precise insertion of PCBs on pins into plastic injection tool,
injection molding with integrated force monitoring,
automated removal, deburring, sprue cutting and optical inspection of finished parts,
safe operator access and long-term autonomous operation.

“We needed flexibility and consistency — Iskra PRO delivered both. Their system helped us scale efficiently while improving quality at the same time.”

Project Implementation

Technical breakdown of the interconnected robotic and mechanical systems:

1. Pin Strip Unwinding and Punching Unit

Automatically unwinding of stripe with pins is lubricated and punched using a custom-built pneumo-hydraulic press. Excess strip material is collected. An integrated oil level sensor ensures safe and reliable operation.
Three pins are picked with ABB 6-axis robot and placed into plastic injection tool. This process is repeated eight times.

2. Empty Blister Tray Loading

PCBs are picked, verified (2D code scan), and inserted onto pins using an Epson SCARA robot.
A servo-driven pressing manipulator ensures precise insertion of PCBs on pins using force sensors.
The unit also cleans mold inserts using compressed air before each cycle.

3. Runner Cutting and Camera Inspection Unit

After molding, ABB 6 axis robot picks mold parts with runner from tool and places it into pneumatic press which removes excess runners.
Each part is then transferred with another Scara robot to fixture in round table.
On station with round table vision inspection is performed with cameras.
Vision equipment and sensors verify parts quality (fill level, pin lenght, etc.).

4. Automated Palletizing & Conditional Part Management

Finished parts are sorted into pallets with another Scara robot.
Automatic pallet system ensures long autonomy of the machine.
Conditionally approved parts are stored separately for further manual verification.
Scrap parts are securely stored in separate box.

5. Input/Output Conveyor System

Dual-belt conveyors allow easy pallet loading and unloading.
Lifting modules enable stacking up to 15 pallets and maintain continuous machine operation for extended periods without operator intervention.