How to customize multi-axis injection molding manipulator?

Customized multi-axis injection molding manipulator needs to consider many aspects, the following are the specific steps:

First, clarify the needs

Production process requirements:

First of all, you need to analyze the characteristics of the injection molding product, such as the size, weight, shape and so on. Different product characteristics have different requirements for the grasping method and gripping force of the manipulator. If the product is small in size and light in weight, it may only need a smaller clamping force and a more flexible grasping mechanism; For large or heavy products, a stronger clamping force and a more stable structure are required.

Understand the injection molding process, including injection cycle, mold structure, etc. The manipulator needs to match the working rhythm of the injection molding machine to ensure that operations such as picking up parts are carried out at the right time. For example, the injection cycle is short, and the action speed of the manipulator needs to be increased accordingly to ensure production efficiency.

Production efficiency requirements:

The working speed and frequency of the manipulator are determined according to the production capacity target of the production line. If the production line requires high output, then the manipulator should have fast movement and short cycle time. For example, for some mass-produced plastic products, the robot may need to be able to complete multiple take-up and placement operations per minute to meet the needs of the production line.

Consider the reliability and stability of the manipulator to reduce downtime. High-quality components and reasonable structural design can improve the stability of the manipulator and ensure its long-term continuous operation. For example, the use of well-known brands of motor, guide rail and other key components, can reduce the probability of robot failure, improve production efficiency.

Space layout requirements:

Measure the layout space of the injection molding machine and peripheral equipment to ensure that the robot can be installed and operated in a limited space. Some production workshops have limited space, and the design of the manipulator needs to be compact, while also taking into account the interference problem with other equipment. For example, if there are conveyor belts, dryers and other equipment around the injection molding machine, the manipulator cannot collide with these equipment during the movement, and its movement trajectory needs to be reasonably planned.

Considering the possible expansion or adjustment of the production line in the future, the design of the manipulator should have a certain flexibility and scalability. For example, some interfaces or installation locations can be reserved for future addition of functional modules or connection with other devices.

Second, choose the right manufacturer

Research the market:

Extensive search for manufacturers of multi-axis injection molding manipulators in the market. You can learn about the products and services of different manufacturers through Internet search, industry exhibitions, professional magazines and other channels. The more well-known injection molding robot manufacturers have Fanuc in Japan, Kuka in Germany, etc., and there are also some excellent domestic manufacturers such as Tuostar.

Check manufacturers' word-of-mouth and customer reviews. You can find out what other users are saying about the manufacturer's products and services through online forums, industry communication groups, etc. Customer evaluation can reflect the manufacturer's product quality, after-sales service and other aspects of the situation, for choosing the right manufacturer is very valuable reference.

Assess technical capability:

Understand the technical research and development strength of the manufacturer, including whether there is a professional research and development team, whether there is an advanced production process and testing means. For example, some advanced manufacturers have their own research and development centers, which are able to constantly introduce new technologies and new products to meet the needs of the market.

Inspect the production capacity of the manufacturer, including production equipment, production scale, etc. Manufacturers with strong production capacity can guarantee the quality and delivery time of products. For example, manufacturers with advanced processing equipment and automated production lines can produce robot products with higher accuracy and more stable quality.

Communication and negotiation:

Communicate in detail with the manufacturer and provide them with your specific needs and requirements. The manufacturer should be able to provide professional advice and solutions according to your needs. For example, the manufacturer may recommend the appropriate type of manipulator, number of axes, range of motion, etc., based on your product characteristics and production process.

Negotiate terms such as price, delivery time and after-sales service. The price should be reasonable, while ensuring that the manufacturer can deliver on time, and provide good after-sales service, including installation and commissioning, training, maintenance and so on. For example, some manufacturers provide free installation and commissioning services and a certain period of warranty, during the warranty period can respond in time and solve the problems encountered by customers.

Third, design and manufacturing

Scheme design:

The engineer of the manufacturer will design the overall scheme of the robot according to the requirements information provided by you. This includes the structural design of the manipulator, the design of the motion system, the design of the control system, etc. The structural design should consider the strength, stiffness and stability of the manipulator to ensure that it can withstand the weight and force when grasping the product. The motion system design should determine the axis number, motion range, motion speed and other parameters of the manipulator to meet the requirements of the production process. The control system design should select the appropriate controller and sensor to realize the precise control of the manipulator.

In the design process, computer-aided design (CAD) and computer-aided engineering (CAE) techniques are used to simulate and analyze the structure and performance of the manipulator. For example, CAE analysis can predict the stress distribution and deformation of the manipulator in the working process, so as to optimize the design and improve the performance and reliability of the manipulator.

Parts procurement and processing:

Depending on the design, manufacturers need to purchase a variety of components, including motors, reducers, guides, sensors, controllers, and more. The quality of these parts directly affects the performance and life of the manipulator, so it is necessary to choose products with reliable quality and stable performance. For example, the use of high-precision motors and reducers can improve the motion accuracy of the manipulator, and the use of high-quality sensors can improve the perception ability of the manipulator.

For some special parts or structural parts, the manufacturer may need to carry out machining. The processing process should strictly control the quality to ensure that the dimensional accuracy and surface quality of the parts meet the requirements. For example, precision machining equipment and processes are used to process key parts of the manipulator to ensure its assembly accuracy and performance.

Assembly and commissioning:

After the parts are processed, the robot is assembled. The assembly process should be carried out in strict accordance with the design requirements and assembly process to ensure that the installation position of each component is accurate and firmly connected. For example, the connection between the motor and the reducer should ensure the coaxiality, and the installation of the guide rail should ensure the parallelism and straightness.

After the assembly is completed, the debugging of the manipulator is carried out. Commissioning includes mechanical commissioning and electrical commissioning. Mechanical debugging is mainly to adjust the motion parameters of the manipulator, such as motion speed, acceleration, position accuracy, etc., so that it can meet the design requirements. Electrical debugging is mainly to debug the control system to ensure the normal work of sensors, controllers and other equipment and the accuracy of signal transmission. The debugging process may require several adjustments and optimizations until the performance of the manipulator meets the requirements.

Iv. Acceptance and training

Acceptance:

The customized multi-axis injection molding manipulator is fully accepted. The acceptance includes the appearance quality, mechanical performance, electrical performance, control function and so on. The appearance quality inspection mainly looks at whether the surface of the manipulator has scratches, rust and other defects; Mechanical performance inspection includes motion accuracy, repeated positioning accuracy, bearing capacity, etc. The electrical performance check includes the operation of the motor, the signal accuracy of the sensor, etc. The control function check includes whether the various actions of the manipulator can be accurately executed according to the predetermined program.

In the acceptance process, the actual production simulation test can be carried out to allow the manipulator to run in a simulated production environment to observe its work and performance. For example, continuous take-up and placement operations are carried out to check the working efficiency and stability of the manipulator. If the problem is found, communicate with the manufacturer to solve it in time until the robot meets the acceptance standard.