When customizing injection molding manipulators, the following safety specifications need to be followed:

First, mechanical structure design safety

1. Strength and stability

The various parts of the manipulator, including the arm, joint, grasping mechanism, etc., should have sufficient strength and stability to withstand various loads and impact forces that may be encountered in the working process. For example, the arm material should choose a high-strength alloy or composite material, and it should be designed through calculation and simulation to ensure that it can not deform or break under the maximum load (such as grabbing the heaviest product, bearing the inertia force of high-speed movement, etc.). In general, in accordance with the relevant mechanical design standards, the strength of the key components should be checked, the safety factor should usually be no less than 1.5, that is, the maximum stress that the parts can withstand is greater than 1.5 times the maximum actual stress that they may withstand in the work.

- The overall structural design of the manipulator should ensure the stability during operation. For example, for arm structures with large spans, support and balancing devices should be reasonably designed to prevent shaking or overturning when extended to the limit position or rapid movement. The stability of the manipulator can be improved by increasing the counterweight and optimizing the structure layout, etc., to ensure that it can operate safely and reliably under various working attitudes.

2. Protective devices

- Install protective devices for moving parts of the manipulator to prevent injuries caused by contact with moving mechanical parts. For example, a protective cover is installed at the joint of the manipulator to prevent the fingers, clothing, etc., of the person from being involved in the rotating joint. The shield should be made of a durable and transparent material to provide effective protection without affecting the observation of the operating state of the manipulator. For the high-speed movement of the arm part, you can use a closed guardrail, the gap of the guardrail should be small enough to prevent any part of the body from entering the dangerous area, while the security door lock and other devices should be set up, only after the manipulator stops running and the guardrail is unlocked, the personnel can enter the maintenance or debugging area.

- Set up protective devices around the grasping mechanism of the manipulator to prevent the accidental drop or splash of the product during the process of grasping and handling the product from causing injury to personnel. For example, for manipulators that may grasp high-temperature products, an anti-scald heat insulation protection plate should be set under the grasping mechanism; For manipulators that grab fragile products, a protective net should be installed to prevent debris from splashing. These guards need to be easy to install and remove, so that they can be operated easily when a grab mechanism needs to be replaced or maintained.

Second, electrical system safety

1. Circuit protection

- Equipped with perfect circuit protection devices for the electrical system of injection molding manipulator, such as overload protection, short circuit protection, grounding protection, etc. The overload protection device should be able to cut off the power supply in time when the load of the motor or other electrical equipment exceeds the rated value to prevent damage to the equipment due to overload or cause fire and other dangers. For example, when the motor load current of the manipulator exceeds 120% of its rated current, the overload protection device should act within a few seconds to cut off the motor power supply. The short-circuit protection device should be able to quickly cut off the power supply when the circuit short-circuit fault occurs, and its operation time should generally be at the millisecond level to minimize the damage of the short-circuit current to the electrical equipment and line. At the same time, the electrical system of the manipulator must have good grounding measures, and the grounding resistance should meet the relevant standard requirements (generally no more than 4 ohms) to ensure that the current can be safely imported into the earth when an electrical failure occurs.

- Reasonable wiring and protection of electrical lines. Electrical lines should be insulated wires that meet standards and routed in accordance with specifications to avoid confusion, crossover or mechanical damage. For example, the power line and the control line are arranged separately to prevent the electromagnetic interference of the power line from affecting the accuracy of the control signal. For lines exposed to the outside of the manipulator, protective sleeves or troughs should be used to protect them from being worn, pulled or eroded by chemicals. At the same time, it is necessary to check and maintain the electrical line regularly to discover and eliminate potential line faults and safety hazards in time.

2. Emergency stop device

- An obvious and easy to operate emergency stop button on the operation panel and key positions of the injection molding manipulator. The emergency stop button should be a red mushroom head button with a self-locking function, which can immediately cut off all the power sources of the manipulator (including power, air, etc.) after being pressed, so that the manipulator can quickly stop running. For example, an emergency stop button should be set on the control panel of the manipulator, around the working area and where the operator is easy to reach, to ensure that in the event of an emergency, the operator can stop the manipulator's action in the first time. At the same time, the function of the emergency stop button should be tested regularly to ensure that it can operate reliably at all times.

- Design reasonable emergency stop control logic, when the emergency stop button is pressed, the manipulator should not only stop the movement immediately, but also ensure that it is in a safe state. For example, for the manipulator that is grasping the product, the grasping mechanism should be released immediately after the emergency stop to prevent the product from falling and causing danger; For the arm in motion, it is necessary to stop it quickly and keep it in the current position through the brake device to avoid secondary accidents such as collisions caused by inertia. At the same time, after an emergency stop, the control system should record the relevant status information so that the situation can be accurately understood when troubleshooting and resuming production.

Three, control system security

1. Program security

- Write safe and reliable program code for the control system of injection molding manipulator. The program should have perfect logical judgment and error handling function, and can detect the abnormal situation in the operation process of the manipulator in time and take corresponding measures. For example, when the sensor detects that the movement position of the manipulator is out of the preset range or the speed is abnormal, the program should immediately stop the movement of the manipulator and issue an alarm signal. At the same time, the program should conduct authority management for key operations to prevent unauthorized personnel from modifying or misoperating the program of the manipulator. For example, if user rights are set at different levels, only high-level users (such as engineers) can modify key parameters of a program, while common operators can only perform basic operations (such as starting and stopping).

- Regularly update and maintain the software of the control system to repair possible vulnerabilities and improve the stability of the system. With the development of technology and the discovery of problems in practical applications, software vendors will constantly release updated versions. These updates should be obtained and installed in a timely manner to ensure that the control system of the manipulator is always in a safe and reliable state. At the same time, before updating the software, the current program and data should be backed up to prevent problems during the update process resulting in data loss or system failure. After the update, the various functions of the manipulator should be comprehensively tested to ensure its normal operation.

2. Security interlock

- Establish a safety interlock mechanism between injection molding manipulator and injection molding machine. The manipulator and the injection molding machine should be able to communicate with each other and coordinate their actions, and when one side fails or is in an unsafe state, the other side can stop operation in time to avoid accidents. For example, when the safety door of the injection molding machine is opened, the manipulator should stop acting immediately to prevent collision with the manipulator when the personnel enter the area of the injection molding machine. At the same time, when the manipulator is faulty or abnormal, it should be able to send a signal to the injection molding machine, so that the injection molding machine can suspend production, and wait for the robot to resume collaborative work after the fault is eliminated. This security interlock can be achieved through a hardware connection (such as a signal line connection) and a software communication protocol, ensuring that both parties can accurately transmit status information in real time.