What problems should be paid attention to in the debugging process of installing injection manipulator in injection molding factory?

Debugging of injection molding manipulator is a key link to ensure its normal operation and give full play to its best performance. During debugging, we need to pay attention to the following issues:

safety-check

Protective device: Check whether the protective devices such as protective fence, light curtain and emergency stop button around the manipulator are installed in place and can work normally. These devices are an important line of defense to ensure the safety of operators, and any failure may lead to serious safety accidents.

Mechanical structure: carefully check whether the mechanical arm, joints, fixtures and other parts of the manipulator are firmly installed, and whether there are signs of looseness, deformation or damage. Any problem in mechanical structure may affect the motion accuracy and stability of the manipulator, and even lead to equipment failure.

Electrical connection and parameter setting

Electrical connection: ensure that the electrical connections of the power cord, signal cord and encoder cord of the manipulator are correct, and there is no looseness, virtual connection or short circuit. The wrong electrical connection may damage the electrical components of the equipment, and even cause safety accidents such as electrical fire.

Parameter setting: According to the specifications of the injection molding machine, the size of the mold and the requirements of the production process, correctly set various parameters of the manipulator, such as movement speed, travel range, grasping strength, residence time, etc. Unreasonable parameter setting may lead to the manipulator's failure to accurately complete the operations of picking and placing parts, which will affect the production efficiency and product quality.

Motion trajectory debugging

Origin and limit: First, determine the origin position of the manipulator and adjust the limit switch to ensure that the manipulator will not exceed the set range during the movement. Inaccurate origin position or failure of limit switch may cause the mechanical arm to collide with other equipment, resulting in equipment damage.

Trajectory planning: Through manual operation or programming control, let the manipulator move according to the preset trajectory, and check whether the movement of the manipulator is smooth and smooth, and whether there is jamming, jitter or abnormal noise. At the same time, it is necessary to ensure that the mechanical arm can reach each target position accurately during the movement and coordinate with the actions of the injection molding machine and the mold. In the process of debugging, it may be necessary to fine-tune the motion trajectory for many times to achieve the best effect of picking and placing parts.

Fixture debugging

Fixture installation: check whether the fixture is correctly installed on the mechanical arm, whether the installation position is accurate and whether the fixation is firm. The installation quality of fixture directly affects whether the injection molded products can be grasped and placed stably.

Clamping strength: Adjust the clamping strength of the fixture reasonably according to the weight, shape and material of injection molded products. Too much force may damage the product, and too little force may cause the product to fall. Through the actual test, the clamping strength can be gradually adjusted until the product can be reliably clamped and placed.

Fixture accuracy: check whether the opening and closing accuracy of the fixture meets the requirements and whether it can accurately aim at the grasping part of the injection molded product. Insufficient precision of fixture may lead to failure of grasping or deviation of product during grasping, which will affect the normal production.

Linkage debugging with injection molding machine

Signal communication: ensure that the signal communication between the manipulator and the injection molding machine is normal, and can accurately receive and send various control signals, such as mold opening signal, ejection signal, manipulator start signal, etc. The failure of signal communication may cause the actions of manipulator and injection molding machine to be out of sync, which will affect the continuity and stability of production.

Action coordination: In the process of linkage debugging, it is necessary to carefully observe whether the action coordination between the manipulator and the injection molding machine is tacit. For example, when the injection molding machine completes the mold opening and ejection, the manipulator should enter the mold in time and accurately to take the parts; After taking the parts, the injection molding machine should be able to smoothly perform subsequent operations such as closing the mold. By constantly adjusting the action time and sequence of the two, the best linkage effect can be achieved.

Load test

Maximum load: In the later period of debugging, it is necessary to carry out load test, gradually increase the load of the manipulator until it reaches its rated load, and check the operation of the manipulator under different load conditions. Including the deformation of the mechanical arm, the current and temperature changes of the motor, the maintenance of the movement speed and accuracy, etc. Load test can check the overall performance and reliability of the manipulator and ensure its stable operation in actual production.

Fatigue test: For the injection molding manipulator running continuously for a long time, it is necessary to carry out fatigue test to simulate the frequent actions in actual production, and observe whether the manipulator has problems such as performance degradation and component wear after a certain number of cycles. Fatigue test can find out the potential trouble ahead of time, and provide the basis for the maintenance of equipment.

program optimization

Production efficiency: according to the actual production situation, optimize the control program of the manipulator to improve its movement speed and work efficiency, but be careful not to sacrifice product quality and equipment safety. For example, the motion path of the manipulator can be arranged reasonably to reduce unnecessary idle travel time; Optimize the time parameters of grasping and placing actions to improve the production output in unit time.

Exception handling: Improve the exception handling function in the program. When the product is not taken out, the fixture is not clamped, and communication is interrupted, it can give an alarm in time and take corresponding protective measures, such as stopping the movement of the manipulator and keeping the current state of the injection molding machine, so as to avoid causing greater losses.