At Röchling Automotive’s Wackersdorf plant, SUMCAB cable assemblies on extraction robots for injection molding machines ensure greater process reliability and enable shorter cycle times. This is made possible by the high wear resistance of the products, which are tailored to the robots’ motion sequences. Rudolf Lietz, Maintenance Group Leader at the plant, also appreciates the cable specialist’s solution-oriented approach and the commitment of its technicians.

Röchling Automotive is a global partner to automobile manufacturers and system suppliers, with over 4,700 employees worldwide. The plastics specialist’s core competencies include aerodynamics, acoustics, powertrain, thermal management, and new mobility concepts across all vehicle segments.

In Wackersdorf, Bavaria, Röchling Automotive Germany SE & Co. KG operates a plant that manufactures innovative plastic components for underbody systems, engine compartments, air intake, air flap control, and air/water management. The plant has primarily supplied customers in southern Germany for about two decades and has significantly contributed to the company’s success. In addition to its main customer, BMW, the plant also serves Porsche, Plastic Omnium, Opel, Hella, Behr, Faurecia, and Magna Steyr.

Previously High Wear and Tear

The articulated-arm robots perform complex and high-speed movements. Additionally, the grippers—often very intricate—must operate in tight spaces. This made cable assemblies for the robots’ media supply particularly prone to wear, resulting in frequent downtimes of the injection molding machines.

Today, the improved process reliability is largely due to cable assemblies from SUMCAB Specialcable GmbH. In early 2016, a SUMCAB sales representative visited the plant to present cable retraction systems for robot teaching pendants. During the meeting, a problem occurred at one of the injection molding machines: the energy supply for an extraction robot failed. Due to the robot’s complex movements, cable breaks had repeatedly occurred in the wrist axis area. The SUMCAB representative pointed out that the company offers appropriate solutions for such problems.

Pilot System Was Convincing

At the next meeting, a SUMCAB service technician joined and proposed a specific improvement. The robot on injection molding machine 18 was equipped with a SUMCAB cable package.

Rudolf Lietz recalls:

“At the pilot system, we replaced the existing cable assembly with a SUMCAB product, and that solved the issue. The SUMCAB package follows the robot’s movements without any problems. Since then, the machine has been running to our complete satisfaction. That convinced us to gradually retrofit all injection molding machines in the plant. With other manufacturers’ cable assemblies, we had bad experiences—they’re just too susceptible to wear.”

Installation and Optimization

SUMCAB not only supplies the cable assemblies but also installs them on the robots and continuously optimizes them during production. After about a month, SUMCAB technicians return to inspect the cable package for wear and ensure everything is properly adjusted, making corrections if necessary.

SUMCAB’s special cable retraction system enables a streamlined routing along the robot. Rudolf Lietz praises it:

“It’s the optimal low-wear media routing—especially for complex robotic applications. This simple but effective system allows the robot’s energy supply to be flexibly managed in length. The cables are always correctly tensioned, so no loops form, which reduces wear. You can tell this solution comes from experience.”

Shorter Cycle Times Possible

Thanks to its wear resistance, the cable package also contributes to higher productivity of the injection molding systems. The guided motion enables shorter cycle times.

“We can now operate at higher speeds because we know the cable assemblies can handle it without damaging the robot or surrounding components,” explains the maintenance expert.

Another major benefit is the easy and quick Plug & Play replacement of the cable assemblies. Röchling’s own maintenance team performs this. Compared to manufacturer solutions that also allow for Plug & Play, SUMCAB’s connectors are easier to handle, saving time during failures and reducing production downtime.

As of October 2017, five robots in the Wackersdorf plant had already been retrofitted. The remaining machines are also equipped with SUMCAB cable assemblies to further improve system reliability. Standardizing on SUMCAB also simplifies spare parts management.

Customer Satisfaction as a Priority

Rudolf Lietz concludes:

“We’re very satisfied with SUMCAB’s products. Their technicians are thorough and do everything possible to find a solution quickly. I especially appreciate that they revisit the site the day after production starts to check everything again. They truly prioritize customer satisfaction on-site. They don’t leave until the system works 100%. We have more joint projects ahead.”