An Integrated Engineering Methodology for the Design and Industrial Validation of a Three-Axis Cartesian Manipulator for Automated Injection Runner Extraction

Industrial automation systems operating within geometrically constrained manufacturing environments require engineering approaches capable of integrating functional requirements, mechanical design, numerical verification, and industrial implementation within a traceable development process. This study proposes and empirically evaluates a requirements-driven engineering framework through the development of a three-axis Cartesian manipulator for the automated simultaneous extraction of four injection-moulded runners. The framework extends beyond the sequential application of established engineering tools by introducing a requirements-to-evidence structure in which measurable industrial requirements govern architecture selection and detailed design, while numerical predictions, controlled experiments, and extended industrial monitoring provide backward verification of requirement compliance. Finite element analysis predicted a global maximum displacement of 0.4453 mm and a displacement of 0.29–0.33 mm in the functionally critical gripper region. The maximum equivalent von Mises stress was 8.8 MPa, corresponding to a minimum safety factor of 39. Experimental measurement by three-dimensional laser scanning, with a nominal resolution of 0.001 mm, indicated a maximum relative displacement of 0.37 mm in the gripper region. Comparison with the upper numerical prediction resulted in an absolute difference of 0.04 mm and a relative deviation of 10.8% with respect to the experimental value. Both the numerical and experimental displacements remained below the prescribed functional limit of 1.0 mm. A controlled validation campaign comprising 1000 consecutive operating cycles showed maximum axis-position deviations of 0.8, 0.7, and 0.5 mm along the X-, Y-, and Z-axes, respectively, within the specified ±2.0 mm requirement, while successful runner extraction was achieved in 99.6% of the cycles. Extended monitoring under regular production conditions covered 38,690 cycles over three months, during which the system achieved 99.1% operational availability, with no recorded collisions or operator safety incidents. These results demonstrate the practical applicability of the proposed framework under the investigated industrial conditions and provide traceable evidence linking initial requirements, engineering decisions, numerical predictions, experimental measurements, and long-term operational performance.