In modern plastic injection molding facilities, floor-to-ceiling space constraints and strict takt-time targets demand flexible robotic intervention. A Double-Cut Arm Manipulator (frequently designated in industrial automation as a double-section telescopic vertical arm robot) solves a critical mechanical challenge: retrieving molded components efficiently within facilities with limited overhead height clearance.
Unlike single-stage manipulators that require excessive vertical clearance above the machine platen, double-cut arms use a dual-stage telescopic belt drive or rack-and-pinion kinematic linkage. This reduces required overhead operating height by 40% to 50% while accelerating takeoff times down to 0.6 seconds.
By dividing the vertical stroke into primary and secondary synchronized telescoping stages, double-cut systems prevent collision with overhead cranes, lighting fixtures, and low ceilings without restricting vertical reach into deep-mold cavities.
Configured with distinct product and runner arms, a double-arm manipulator simultaneously extracts finished parts via vacuum EOAT (End-of-Arm Tooling) while taking sprue gates via mechanical grippers, reducing total cycle time significantly.
Utilizing high-torque Absolute AC Servo Drives on all 5 axes (X, Y, Z traverse, plus double vertical arms), systems like the Zhiyi WKG-1000 achieve micro-meter positioning repeatabilities of ±0.02 mm.
| Model / Specification | Target IMM Tonnage | Vertical Arm Configuration | Payload Capacity | Dry Cycle Time | Repeatability |
|---|---|---|---|---|---|
| WKG-1000 Series | 300T – 650T | 5-Axis Double-Arm Double-Section | 5.0 kg - 8.0 kg | 0.65 sec takeoff / 4.5 sec total | ± 0.02 mm |
| WKG-1500 Bullhead | 650T – 1300T | 3-Axis / 5-Axis Heavy-Duty Telescopic | 12.0 kg - 15.0 kg | 0.85 sec takeoff / 5.2 sec total | ± 0.03 mm |
| WKFI-950 Servo | 150T – 350T | 5-Axis Servo Double Arm Single/Dual Section | 3.5 kg - 5.0 kg | 0.52 sec takeoff / 3.8 sec total | ± 0.015 mm |
| Large Tonnage Heavy Line | 1500T – 2300T | High-Rigidity Steel Structure Telescopic | 25.0 kg - 40.0 kg | 1.40 sec takeoff / 7.5 sec total | ± 0.05 mm |
Each system incorporates optimized aluminum extrusion beams reinforced with high-rigidity linear guide rails, eliminating mechanical vibration during ultra-fast acceleration stops up to 10 m/s².
Injection molding facilities across North America, Europe, and Asia face chronic shortages of skilled machine operators. Installing automated OEM double-cut arm manipulators facilitates 24/7 continuous "lights-out" production runs without human fatigue or manual part dropping risks.
Manual part removal often incurs cosmetic damage, oil contamination, or mold damage due to premature clamp closures. Precision servo extraction ensures constant mold opening times, stabilizing plastic shrinkage rates and cutting internal scrap rates below 0.15%.
Equipped with kinetic energy regeneration units, Zhiyi double-cut manipulators capture deceleration energy and feed it back into the bus capacitor system, reducing factory power usage by up to 22% compared to standard pneumatic-hydraulic extractors.
In today's rapidly developing industrial automation field, Zhejiang Zhiyi Intelligent Robot Co., Ltd. has become an industry leader through continuous innovation and core engineering strength. Established in 2017, Zhiyi came into being against the backdrop of Industry 4.0, aiming to transform manufacturing efficiency through intelligent robotic solutions.
Beginning with high-speed truss manipulators for daily thermal products, the company expanded its R&D into complex articulated multi-axis robots, automatic packaging lines, and high-performance injection molding manipulators. Today, Zhiyi holds the honorary status of "National High-Tech Enterprise", backed by 13 utility patents and proprietary motion control algorithms.
Zhejiang Zhiyi leverages the world's most concentrated precision machinery industrial cluster in Zhejiang Province, China. This supply chain ecosystem grants significant competitive advantages to global OEM buyers:
From CNC structural milling and aluminum extrusion treatment to electrical cabinet assembly and hardware harness testing, 90% of sub-components are manufactured or sourced within a 50km radius, shortening OEM lead times to 15-20 days.
Zhiyi manipulators incorporate international premier standard hardware: Japanese Shimpo planetary reducers, THK linear motion guides, THK/SMC pneumatic components, and Innovance/Schneider servo drive electronics.
Global buyers achieve Japanese/European quality standards and component reliability at a 35% to 50% capital cost reduction, dramatically shortening factory machinery ROI periods.
All Zhiyi robotic manipulators fully comply with European Machinery Directive 2006/42/EC, Low Voltage Directive 2014/35/EU, and EMC Directive 2014/30/EU. ISO 9001 certified quality control governs every step from raw frame welding to final 72-hour continuous burn-in load testing.
Equipped with standardized Euromap 67 / Euromap 12 and SPI plug-and-play interfaces, Zhiyi double-cut manipulators integrate effortlessly with any injection molding brand worldwide, including Engel, KraussMaffei, Arburg, Haitian, Yizumi, and Sumitomo Demag.
Through integrated IoT gateway modules, remote engineers can perform real-time parameter tuning, firmware updates, and troubleshooting globally. Additionally, Zhiyi maintains regional technical offices across Southeast Asia and partner service hubs in Europe to guarantee 24/7 technical dispatch.
Utilized in large 1000T to 2300T injection presses molding automotive bumpers, dashboards, door panels, and HVAC ducts. The double-cut dual arm safely extracts large structural parts while performing downstream degating, weight verification, and conveyor placement.
Ideal for high-speed multi-cavity food container molds, thermos cups, and lunch boxes where takeoff cycle time must stay below 0.8 seconds. Coupled with in-mold labeling (IML) automation, Zhiyi manipulators guarantee zero scratch risks.
Designed with grease-free enclosed linear guides, stainless steel hardware, and particulate-free vacuum lines meeting Class 100,000 cleanroom requirements for syringe barrels, petri dishes, and diagnostic cartridges.
Customized gripper systems handle complex insert loading (such as placing metal pins or threaded brass bushings into plastic housings before shot execution) for washing machine panels, air conditioner units, and small kitchen tools.
Future double-cut manipulators will incorporate 2D/3D vision cameras directly onto the EOAT arm. AI deep learning algorithms perform immediate inline defect inspection (flash detection, short shots, color variance) during the 2-second traverse stroke, dropping defective parts into reject bins automatically.
Instead of static speed parameters, modern controllers actively analyze payload inertia upon gripper closure, dynamic torque feedback, and vibration sensor data to adjust acceleration curves in real-time, prolonging mechanical life cycles by over 30%.
Adhering to Industry 4.0 standards, Zhiyi manipulators output real-time cycle data, motor temperature telemetry, power consumption metrics, and predictive maintenance alerts directly to cloud-based Manufacturing Execution Systems (MES) via OPC UA protocol.
ZHIYI Robotics
