The new Visual 4: more powerful, even greater connectivity, easier to use

The modern, lightweight control panel of Sepro Group's latest Visual 4 robot controller offers plastic injection moulders access to an even more intuitive, powerful and networkable control platform. The new controller will be unveiled at K 2025, which takes place from 8 to 15 October in Düsseldorf, Germany, and will be available for all Sepro robots from 2026.

The Visual 4 controller will be used to programme most of the robots at the Sepro stand. In a special demonstration area, injection moulders will be able to gain initial practical experience and see for themselves how user-friendly the new controller is. Visual 4 is the latest generation of controllers for Sepro robots, developed specifically for plastic injection moulding. The development included new hardware and software solutions with advanced practical functions. It is fully compatible with existing Sepro controllers and previous programming, so users of earlier Visual versions only need a short briefing to familiarise themselves with the new user interface (HMI). The new control system offers simplified and user-friendly operation and programming for both part removal and downstream peripherals around the injection moulding machine.

The new Visual 4 control system is available in three configurations covering the entire spectrum of possible injection moulding applications:

• Visual 4 is the basic configuration for simple pick-and-place applications and includes control of up to 5 axes and 24 inputs/outputs (I/O).
• Visual 4 Plus supports more application programmes, has additional I/Os and further interfaces for peripheral devices such as conveyor and separation systems, etc.
• Visual 4 Pro is intended for application-specific injection moulding cells with interfaces to multiple robots, peripheral devices and specially configured robot types.

Newly designed, lighter control panel
The new Visual 4 control system has a control panel that is 25% lighter than the previous version, Visual 3, making it more comfortable and easier for operators to use during programming. The weight reduction is primarily due to the CPU board being integrated into the robot control cabinet. This also improves data security and reliability, as critical components are better protected from damage.
The digital screen of the Visual 4 control system has an aspect ratio of 10:16 compared to 4:3 in the Visual 3 control system. The rectangular screen in portrait rather than landscape format offers a larger display without affecting the overall dimensions of the control panel.

Like the screens of smartphones or tablets, the display of the Visual 4 control system is also designed as a touchscreen with better responsiveness and higher accuracy and supports multi-touch gestures. The layout is more modern, clearer and works with a higher-contrast background. In addition, the HMI navigation has been designed to allow faster access to submenus and
navigation pages, which shortens programming time. The control panel has 22 haptic quick access keys for basic commands such as start/stop cycle, axis movement, etc. These keys eliminate the need for a joystick, enabling more intuitive teaching and robot movements across multiple axes.

Powerful and flexible
In addition to improved navigation and ergonomic functions, the Visual 4 control system also features a powerful Intel x86 processor for controlling up to ten axes, enabling the implementation of even highly complex injection moulding cells. These can include one or more injection moulding machines, interfaces to multiple robots in different configurations, and peripheral devices. Tasks such as assembly, marking, inspection, packaging, etc. can also be integrated into the processes. Up to 1,000 process programmes can be stored in the system and retrieved.
‘What distinguishes and sets the Visual 4 control system apart from those of other suppliers is the same thing that has distinguished Sepro's control systems since we began developing robots,’ says Dirk Schröder, Managing Director of Sepro Germany and CTO Automation of the Sepro Group. "It was developed by our engineers to meet the very specific requirements of our customers in the plastic injection moulding world. It fits every robot series and can be integrated into new or existing injection moulding machines and any subsequent automation, regardless of the manufacturer. The new Visual 4 control system builds on all our experience and expertise from the last 50 years and complements this with modern technology and the latest knowledge. It offers exactly the performance, flexibility and user-friendliness that injection moulders need today to be successful."

Secure and compatible
The safety features of the new Visual 4 control system include user profile settings and authentication profiles that determine which users or user groups have access to specific functions or applications. The new Visual 4 control system is fully compatible with existing EUROMAP standards and is also future-proof with regard to new standards that are to be introduced in the medium term.