Robots and

Automation Systems
Reliable and Fast Part Handling
world of innovation
WITTMANN Robots
Leading Worldwide with the Best Technology

Decades of application experience, innovative developments and more than 35,000 produced units have made the
WITTMANN robots what they are today – the best robots for the plastics industry! Well planned detailed solutions and
state-of-the art components allow highest reliability, shortest cycles and long intervals between maintenance.

BUS technology
All sensors/actuators at the robot are directly wired to the
intelligent control card under the robot hood.
Advantages
Central operation via TeachBox.
Simple extension; adaptability. Rail guides
Low-maintenance
execution for lubrication
intervals of about 1 year.
Demolding stroke (X-axis)
A large aluminum extrusion provides a stiff, vibration free foundati-
on. The vertical arm is directly flanged on the cross tube. The linear
bearings for horizontal stroke and demolding stroke are positioned
in the main carriage next to each other to allow for high speed
operation.
Advantages
Reduction of
vibrations.
Most precise
insertion/removal.

Powerful servo drive

Servo drives are used
on all main axes.

Additional rotational axes (optional)

A-Servo or pneumatic.
» B-Servo 0–270°.
Horizontal stroke Vertical stroke (Y-axis)
(Z-axis) Advantage
95% of all robots are working using a rack Massive aluminum or steel The point of the removal activity
and pinion drive. This is avoiding expansions execution depending on the is easily changeable from the nozzle
of the drive belt when acceleration an dece- dimensions of the units. side to the ejection side.
laration are taking place. Optimal lubrication Always driven via rack and
and life span of the drive system due to the pinion drive or drive belt,
pinion‘s placement within a grease cage. telescopic axes are driven by
a combination of both.
Advantage
Expansion of the drive belt is avoided, Advantages Swivel axis (C-axis)
especially in case of long strokes. Torsional stiffness through For nearly all scales equipped with
high-strength construction. locking bolts. This avoids the devi-
B-axes can be directly integ- ation when a decrease in pressure
rated into the profile. occurs.
Possibility of placing the
compressed air supply and
the control lines internally.

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 The Innovative Robot Concept

We have a wide range of robots

that will meet the best of any of your design needs.

Kick-forward design Kick-back design

»» No moving parts behind platen. »» Heavier payload.
»» Clearance for obstructions such as dryer hoppers, »» Less overall height.
catwalks, building columns.
»» Allows for oversized end-of-arm tool.

Integrated control cabinet

Use of state-of-the-art compact servo modules integrated on the robot
itself eliminates the need for an external control cabinet. The integrated
control cabinet is mounted behind the horizontal axis for valuable
space savings in the molding shop.

»» Space saving.
»» Short motor and encoder cables.
»» Less cables and connections to fail.
»» Highest reliability of robot operation.

The integrated control cabinet allows electrical connection of external

I/O-modules via a bus cable for the direct control of all attached
peripheral equipment.

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W8 pro Robot Series

The new pro series takes the WITTMANN W8 robot series

to a whole new level of performance. – Countless improvements
guarantee the highest efficiencies.

»» Rugged design of the robot.

»» Modularity of the robot mechanics and of the drive and control system architecture.
»» The elaborate modular WITTMANN robot design allows for an optimal cost/performance ratio.

Advantages
»» Reinforced profiles for higher load rating and longer durability.
»» ambiLED indicator lamp for simple display of the robot‘sb operating modes.
»» EcoVacuum: synchonized vacuum for optimizing the consumption of pressurized air.
»» Minimized number of cables in the cable chain through innovative decentralized arrangement of the electronic components.
»» Reduced noise emission through optimized cable chain.
»» Integrated energy storage for higher energy efficiency, creating typical savings of 20%.
»» Integrated connection technology for vacuum/gripper circuits.

Features
ambiLED indication lamp shows three different
operating modes.
– 1. Green signal: robot works in automatic mode.
– 2. Blue signal: manual intervention is necessary.
– 3. Red signal: safety door open.

»» Integrated connection technology for vacuum

and gripper circuits.
»» Optimized cable chain.
»» Integrated control cabinet
»» For minimizing the space requirements beside
the injection molding machine.

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 R8 Robot Control and TeachBox

The control offers the user a comfortable graphical user interface via the touch-screen
TeachBox for direct selection of all functions. To avoid unintended operation, the TeachBox
can be unplugged from the sub-pendant which contains the main operating functions
of the robot. Teach programs can either be saved via the integrated USB-port – on the
memory stick provided – or on an integrated flash card memory.

Advantages
»» Shortest training time for personnel.
»» Free programming of every robot operation.
»» Infinite diagnostic possibilities of the robot functions.
»» Integrated observation of maintenance intervals.
»» Different programming levels for the respective user profile.

Total Flexibility
The control system offers 2 levels of operator interface as standard.

QuickEdit for the modification of a few select commands and, TextEditor for ultimate programming freedom. This allows
any arbitrary robot sequence to be programmed via simple, intuitive menu navigation. Neither editor needs command codes,
the designated functions are executed directly at the robot and are transferred via one keystroke into the program. The
naming of the peripheral inputs and outputs, cylinders, grippers, and vacuum cycles facilitates the readability and allows
for a clearly arranged program structure. Pick & Place and other simple programs can be defined using the new QuickNew
function. QuickNew is an animated programming tool that supports the user in setting up a QuickEdit program.

QuickNew QuickEdit

»» Ethernet interface for the connection to a companywide

intranet or internet.
»» EcoMode: automatic optimization of axes velocities outside
of the mold for smooth operation of the robot.
»» Patented* SmartRemoval function: shortest part removal time
through acceleration of the vertical arm during mold-open
motion. [*SmartRemoval Patents: EP 2560802B, US 9387614
CN 102858515]
»» Freely programmable safety areas: the user can define the
areas of robot motion to avoid collisions with components
iVac of the IMM during manual mode.
»» iVac: allows programming of limit values for the vacuum in
TextEditor
order to provide part pecognition in the end-of-arm-tooling.
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Net8 Sprue Picker Control

»» For WP80 sprue picker.

»» Easy to use interface with graphical LCD display. Arrangement
of buttons and symbols is similar to the CNC TeachBox for
easier use by the operators.
»» Simple sequence start.
»» Simple Teach-In programming of the entire program
sequence, including all movements, strokes, time settings
and molding machine interface.
»» 4 standard programs for easy setup.
»» Up to 50 additional individual programs can be
taught and stored.
»» Standard molding machine interface (SPI & E12).
»» Full diagnostics with text error messages.
»» The same languages as with the R8 control are available.

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 Small Robots
Clamping Forces from 20 to 300 Tons

In this range, WITTMANN offers robots of both concepts, units with fixed
and moving demolding axis, but in most cases devices with fixed axis.

»» W808/818
The universal robot providing flexible automation for your current
and future requirements on smaller molding machines.
High performance robots featuring servo motor drives for all three
main axes.
Optional rotational axes allow additional flexibility.
Extremely smooth operation with lowest noise.
Minimum part removal times are essential for the highest producti-
vity of the automation cell e.g. production of thin wall components.
The vertical arms of the W818 and W818T model robots are stiff
but lightweight ribreinforced aluminum profiles, driven via belt by a
servo motor, thus reducing the moving mass.

W818

W823
»» W821
The vertical arm consists of a rigid aluminum extrusion and guided
by heavy-duty linear bearings and driven by a servomotor via belt
to allow high speeds and short removal times. As a variation of the
W821, the W831 model with an extended demolding stroke of up
to 800 mm is available.
»» W823
Telescopic vertical axis: the gripper is mounted in front of the
telescopic arm allowing for a very short length, for minimum overall
height and fast movements.

W821

»» W828
Design is comparable to the W818 unit. Longer demolding
axis for tandem molds. Offers the possibility of a double arm
allowing to remove the sprue separately (3-platen-mold). The W828
long X-axis is designed to also execute preparation steps.

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Middle Series
Clamping Forces from 300 to 1,200 Tons

Middle series robots are primarily units that are equipped with a moving demolding
stroke. In the first line, this is due to the more complex grippers that are used within this
range, and also to the need of keeping the overall height of the system rather compact.

»» W822
Rack and pinion drive for the vertical axis. The W822 can handle
15 kg of payload on strokes of either 1,000 mm or 1,200 mm and
12 kg when fitted with the 1,400 mm axis option.

W822

»» W832 pro
The vertical arm is a rigid aluminum extrusion with two high
load linear bearings and a maximum length of 1,600 mm (63").
Designed for payloads of 30 kg (77 lbs.) and offering a high torque
C-axis rotation for placing. A popular robot for insert jobs.

W832 pro

»» W833 pro
Gripper and part weight of 20 kg (44 lbs.) with a maximum vertical
stroke of 1,800 mm (71"). Therefore best suited for flexible automa-
tion on injection molding machines up to approximately
900 tons.

W833 pro

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 Large Robots
Clamping Forces from 1,200 to 4,000 Tons

Large units are based nearly exclusively on the technology of the moving
X-axis. In the first line, this is due to the massive grippers and additional rotating
axes. As parts of automation cells, these units often are working together
with more compact models to execute preparation or post-processing steps.

»» W842 pro
For greater payload and versatility around molding machines of up
to 800 tons of clamping force.

»» W843 pro
The larger more substantial main beam and double walled kick W843 pro
stroke extrusion for payloads of 30 kg (66 lbs.) and vertical
strokes up to 2,600 mm (102") for palletizing on pallets located
on the shop floor.

»» W853 pro
For payloads of 40 kg (88 lbs.). The first robot with rack-and-pinion
drive and steel profile at the demolding axis. The vertical telescopic
axis is composed of a newly developed steel-aluminum combination.

W853 pro

»» W863 pro
For payloads of 60 kg (132 lbs.). All main axes are made of steel,
thus the highest rigidity is guaranteed. This robot is often used with
injection molding machines of 1,600—2,400 t of clamping force.

W863 pro

»» W873/883
For payloads of 110 kg (243 lbs.) [W873] or 130 kg (287 lbs.)
[W883] respectively. The construction elements of the complete
robot system is made of steel. This allows for highest stiffness and
life expectancy. This unit is especially suitable for the use with large
W873
injection molding machines.

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Fastest Removal

The ultra high speed robot series has been developed to achieve the fastest
part removal times and allows mold open times of less than 1 second.

In order to constantly achieve these short removal times over the long
term, the vertical axis is activated directly over a planetary gear box
engaging with a generously dimensioned tooth belt. This guarantees
direct transfer of forces as well as minimizing the moving masses. For
mechanical absorption of the high acceleration and deceleration forces
of up to 65m/s2, the vertical axis is designed with an extremely torsion
stable kick stroke which is internally reinforced with ribs. The vertical
axis consists of an aluminum profile which by means of finite element
analysis, is designed for the lightest weight and highest stiffness.
W821UHS

Advantages
»» Highest productivity of the injection molding machine with the shortest cycle.
»» Minimizes all moving masses for the highest acceleration and deceleration.
»» The moving X-axis is further improving the dynamic of the units.

»» W837
The larger W837 model has been developed for fastest horizon-
tal axis motion on molding machines up to 700 tons clamping
force. This side entry robot can handle a payload of up to 50 kg
for each horizontal axis.

W823D

Robots
for stack molds
On the one hand, for the automation of stack molds,
robots with 2 vertical axes can be used; here, the
construction is done over a fixed demolding axis
W837, execution (W823D). On the other hand – and for the realization
with 2 Z-axes
of shortes cycle time –, removal systems can be used
that are based on teh W837 unit. In this case, the
basic system is executed with 2 horizontal axes that
are doing the demolding of the parts.

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 Packaging solutions
with IML Technology

In this field, the WITTMANN customers are focused on the planning and
implementation of complete turnkey systems. Here, WITTMANN offers complete
automation cells on the basis of horizontal and vertical parts removal units.
These systems cover a wide range of use, from rather simple ones to highly com-
plex systems that also include the handling of lids and camera control.

Example of a vertical production

cell in the field of packaging:
­manufacturing of paint buckets.

W837
Complete cell including
camera control and stapling unit
for food containers.

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Sprue Picker
Clamping Forces from 25 to 300 Tons

WP80 sprue picker: for the removal of sprues and parts

from the injection molding machine. The solid construction
allows fast movement with low vibration for precise removal.
»» X-axis (kick-stroke)
– Heavy-duty linear rails and recirculating ball bearings.
– Swivel base to rotate the arm behind the fixed platen
for mold changes and locating pin to precisely reposition
arm for part removal.
»» Y-axis (vertical stroke) 0–550 mm (21.7") or 700 mm (27.6")
– Adjustable stroke.
– Pneumatic shock absorbers.
– Locking cylinder to prevent the arm from drifting down
into the molding in the event of air pressure loss.
– The Y-axis is also equipped with a heavy-duty switch
as an additional interlock before the mold can close.
Energy chain for less wear of tubing.
»» Z-axis (pivot)
– Freely adjustable from 45°–95°.
– Simple changeover from rear side to operator side placement.
»» B-axis (90° tooling rotation)
– Rotation is made automatically when pivoting the Z-axis
out of the press.
– Mechanical sprue gripper with part monitoring.
»» Mechanical sprue gripper
– with part monitoring.
»» Options
– Venturi vacuum with part monitoring.
– Parts gripper with 4 suction cups.

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 Additional Options

For applications with additional degrees of freedom, WITTMANN supplies

optional servo rotational axes around all 3 principle axes. Programming with
increments of 0.1° ensures extremely fine adjustment.

»» Servo A-axis
Allows the wrist flip to independently position the end-of-arm tooling and
molded parts, i.e. in the mold area as well as during placement.
»» Servo B-axis
Allows rotation of the end-of-arm tooling in the mold area between the
fixed and flexible adapter plate and the arbitrary orientation of parts with
a flip-down gripper during placement.
»» Servo C-axis
Allows removal of molded parts from the moving as well as the fixed mold B-Servo+C-Servo
halves and the arbitrary presentation to downstream equipment.
»» Advantages
– Compact mechanical design minimizes mold open.
– Highly dynamic servo motors and precise planetary gearboxes enable ­
extremely fast movements.

A-C-Servo

Control of
Downstream Equipment
The universal WITTMANN TeachBox R8.3 robot control systems
provide multiple enhancements and interfaces for the integration
of peripheral and downstream equipment. This increases the per-
formance of the overall system and allows central access to all
functions via the robot TeachBox.

Examples of interfaces
»» Up to 8 independent signals for programmable conveyor
indexing.
»» Control of up to 32 vacuum and simultaneously 32 gripper
circuits for the realisation of complicated end-of-arm tooling
functions.
»» Extensions of the control with decentralized I-/O modules
on the robot and in the control cabinet.
»» Connection of external decentralized
I-/O modules via CAN-Bus.
»» Mirroring of the TeachBox across
Intranet/Internet via VNC.
»» Email function.
»» R8 CLI – Interface for connection
with ERP system.

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Technical Specifications

Fixed Movable Single Telescopic

Payload Z-stroke X-stroke Y-stroke
X-axis X-axis Y-axis Y-axis
[kg] [mm] [mm] [mm]
W808 3 yes − yes − 1,250–2,000 440 600–1,000
W818 6 yes − yes − 1,250–2,500 420–620 800–1,200
W818T 6 yes − − yes 1,250–2,500 390–590 800–1,000
W821 12 − yes yes − 1,250–4,000 350–550 800–1,400
W822 15 − yes yes − 1,250–4,000 350–550 1,000–1,400
W823 12 − yes − yes 1,250–4,000 350–550 800–1,400
W828 12 yes − yes − 1,500–3,000 905–1,105 1,200–1,400
W831 12 − yes yes − 2,000–5,000 800 1,000–1,400
W832 pro 30 − yes yes − 2,000–6,000 500–900 1,200–1,600
W833 pro 20 − yes − yes 2,000–7,000 500–900 1,200–1,800
W842 pro 30 − yes yes − 2,500–9,000 1,200–1,400 1,400–1,600
W843 pro 30 − yes − yes 2,500–9,000 1,200–1,400 1,600–2,600
W853 pro 40 − yes − yes 2,500–9,000 1,200–1,500 2,000–2,600
W863 pro 60 − yes − yes 3,000–9,000 1,200–2,000 2,400–3,000
W873 110 − yes − yes 5,000–9,000 2,000 2,800–3,600
W883 130 − yes − yes 5,000–9,000 2,000–3,000 2,800–3,600
W821 UHS 3 − yes yes − 1,500–2,500 500 800–1,200
W832 UHS 7 − yes yes − 2,000–4,000 500–900 1,200–1,600
W833 UHS 5 − yes − yes 2,000–4,000 500 1,200–1,400

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WITTMANN Technology GmbH
Lichtblaustrasse 10
1220 Vienna | Austria
Tel.: +43 1 250 39-0
info.at@wittmann-group.com
CNC Robots | Article number: BP00000010 (English) | 2021/10 | Subject to change. | Printed in Austria.
www.wittmann-group.com