Product Descriptions
General Overview - Positioning of the BOY LR 5 Handling System
The BOY LR 5 is a high-precision handling system specifically developed for injection molding machines. It features servo-driven linear axes and is designed for part removal from the mold, runner separation, insert placement, and transfer of molded parts to conveyors or stacking stations.
Fully compatible with Dr. BOY injection molding machines, the BOY LR 5 is a core automation component of integrated production cells consisting of the injection molding machine, handling system, and protective enclosure.
Kinematic Structure and Axis Configuration
The BOY LR 5 handling system is configured as a five-axis system, consisting of three servo-driven linear axes and two pneumatic rotary axes.
Linear axes:
- X axis: part removal stroke from the mold
- Y axis: vertical movement
- Z axis: horizontal transfer and longitudinal movement
Pneumatic axes:
- C axis: rotary axis with a range of 0° to 90°
- B axis: swiveling axis with an adjustable range of 0° to 180° around the Y axis
This configuration allows molded parts to be removed, rotated, oriented, and placed with high positional accuracy at the desired destination.
Servo-Driven Linear Axes and Motion Dynamics
The linear axes of the BOY LR 5 are driven by servo motors via toothed belt systems. This drive concept provides:
- Stable motion at high speeds
- Synchronous movement across multiple axes
- Long service life with low maintenance requirements
- High-precision positioning
Simultaneous axis movements significantly reduce cycle times and increase overall production efficiency.
Positioning Accuracy and Repeatability
The BOY LR 5 handling system achieves a high level of repeatable accuracy verified through long-term measurements.
Technical accuracy specification:
- Positioning accuracy: ±0.1 mm
This precision is particularly beneficial for handling technical components, medical products, and injection molded parts with tight tolerances.
Payload Capacity and Mechanical Loads
The BOY LR 5 is designed for stable operation within a defined payload range, including the part and gripper.
Payload capacity:
- Maximum effective load (part + gripper): 5.0 kg
This capacity covers the majority of small and medium-sized injection molded parts, including those produced in multi-cavity molds.
Axis Strokes and Speed Parameters
The linear axes of the BOY LR 5 are available with various stroke options to accommodate different applications.
X axis (part removal):
- Stroke: 300 mm / 500 mm
- Speed: 1.1 m/s
Y axis (vertical movement):
- Stroke: 600 mm / 800 mm / 1000 mm
- Optional telescopic Y axis: 800 mm
- Speed: 2.0 m/s
Z axis (transfer stroke):
- Stroke: 950 mm / 1100 mm / 1500 mm
- Speed: 1.5 m/s
These parameters ensure compatibility with a wide range of mold sizes and injection molding machine clamping forces.
Pneumatic Rotary Axes and Functional Movements
C axis:
- Rotation angle: 0° to 90°
- Pneumatic torque: 24 Nm
B axis:
- Swivel range: 0° to 180°, adjustable
- Pneumatic torque: 2.2 Nm
These axes allow parts to be oriented correctly before placement on conveyors, stacking systems, or downstream processes.
Vacuum and Gripping Systems
The BOY LR 5 is equipped as standard with two vacuum circuits. These circuits can be used for:
- Vacuum grippers
- Alternatively, pneumatic gripping systems
Optionally, the number of pneumatic circuits can be expanded to a total of eight, enabling control of additional peripheral equipment and extended automation functions.
Control System - Procan LR 5 and Integration
The BOY LR 5 operates with the Procan LR 5 control system featuring a 10.4-inch TFT display. The graphical programming interface allows:
- Easy programming of handling movements
- Shared data usage with the injection molding machine
- Monitoring of process parameters from a single interface
Communication between the injection molding machine and the handling system is managed via a dedicated safety and interface package. Using VNC technology, the handling screen can also be displayed directly on the BOY injection molding machine's control panel.
Electrical and Mechanical Interfaces
Electrical connection:
- EM 67 / EM 18 interface standards
Power supply:
- 400 V AC
- 50 Hz
- 16 A
This configuration provides a stable, safe, and standards-compliant electrical infrastructure.
Safety and Protective Systems
The BOY LR 5 can be supplied with various optional safety components to ensure safe operation within injection molding cells:
- Powder-coated metal safety enclosure
- Secure access doors
- Light barriers
- Manual part removal switch
When combined with protective guarding and conveyor systems, the BOY LR 5 enables the creation of a fully enclosed and safe production cell.
Application Areas
The BOY LR 5 handling system is widely used in the following applications:
- Automatic part removal from injection molds
- Runner separation and part transfer
- Insert placement
- Placement of parts onto conveyors
- Cellular manufacturing and automation solutions
Conclusion - Why Choose the BOY LR 5?
The BOY LR 5 handling system provides a reliable automation solution for injection molding operations, offering high positioning accuracy, servo-driven linear axes, flexible stroke configurations, and strong integration capabilities. Its compact design, modular configuration, and user-friendly control system make it suitable for both simple part removal tasks and more complex automation cells.
For manufacturers aiming to reduce cycle times, enhance process reliability, and achieve consistent part quality in injection molding operations, the BOY LR 5 represents Dr. BOY's engineering expertise in advanced automation and handling technology.
