What should be paid attention to when installing a large injection manipulator?

The installation of large-scale injection molding manipulator is a process that needs careful operation. The following are some matters needing attention:

First, the preparation before installation

Site and environmental inspection

Space requirements: Ensure that the installation site has enough space to accommodate the manipulator and its supporting equipment. The extension range of the manipulator should be considered, including the front and back, up and down, left and right movement space, to avoid collision with surrounding equipment, walls or other obstacles. For example, for an injection molding manipulator with a horizontal stroke of 3 meters, at least a barrier-free space with a radius of 3.5 meters should be reserved around its installation position.

Environmental conditions: the installation site should be kept dry, clean and well ventilated. Avoid installation in humid or corrosive gas environment, because this may damage the electrical components and mechanical parts of the manipulator. At the same time, attention should be paid to the ambient temperature, which is generally recommended to be between 5 and 40℃. Extreme temperature may affect the performance and accuracy of the manipulator.

Foundation stability: the manipulator needs to be installed on a solid and flat foundation. If the foundation is unstable, vibration may occur during the operation of the manipulator, which will affect its positioning accuracy and service life. For the large injection manipulator, its own weight is heavy, and it may be necessary to reinforce the ground of the installation site, such as pouring concrete foundation.

Equipment inspection and inventory

Before installation, carefully check whether all parts of the manipulator are intact. The inspection contents include whether the mechanical arm, joints, fixtures, motors, sensors and other components are deformed, damaged or lack of parts. At the same time, according to the equipment list, carefully count all the accessories and tools to ensure that there are no omissions. For example, check whether the jaws of the fixture can be opened and closed normally, and whether the cable of the sensor is complete.

Tools and personnel preparation

Tool preparation: prepare all kinds of tools needed for installation, such as wrenches, screwdrivers, calipers, level meters, etc. For the installation of large parts, cranes or forklifts may be needed to assist in handling. Ensure the accuracy and integrity of tools, for example, the accuracy of calipers should meet the requirements of measuring the installation size of manipulator.

Personnel arrangement: arrange experienced installers to operate, who should be familiar with the structure and installation process of injection molding manipulator. In the installation process, it may be necessary for electrical engineers, mechanical engineers and other professionals to work together to ensure that all aspects of the installation work can be handled professionally.

Second, the main points in the installation process

Installation of mechanical parts

Positioning and leveling: When installing main components such as mechanical arm, use tools such as level to ensure its installation position is horizontal. Accurate positioning is very important for the motion accuracy of manipulator. For example, when installing the base of a mechanical arm, the levelness error should generally be controlled within 0.1-0.2 mm per meter. Accurate leveling can be achieved by adjusting anchor bolts or gaskets.

Fastening connection: the connection between all parts should be firm and reliable. Tighten the bolts with suitable tools according to the torque requirements provided by the equipment manufacturer. Excessive tightening may damage threads or parts, while insufficient tightening may lead to loose parts and affect the normal operation of the manipulator. For example, the tightening torque of high-strength bolts connecting the joints of mechanical arms should be strictly controlled according to the specifications and grades of the bolts.

Joint installation and debugging: when installing joints, pay attention to the flexibility and accuracy of joints. Check the lubrication of joints and add proper amount of lubricant to ensure smooth rotation of joints. At the same time, the range of motion of the joint is debugged to meet the design requirements. For example, by adjusting the limit switch of the joint, the rotation angle of the manipulator is controlled within a specified range.

Electrical system installation

Wiring specification: electrical wiring should be carried out in strict accordance with the electrical schematic diagram and wiring specification. Cables with different functions (such as power line, signal line, control line, etc.) should be laid separately to avoid signal interference. The cable shall be installed in the cable tray or trunking, and shall be well fixed to prevent the cable from pulling or wearing during the movement of the manipulator. For example, the signal line should be shielded cable, and the shielding layer should be well grounded to reduce electromagnetic interference.

Installation of electrical components: correctly install electrical components such as motors, drivers and controllers. When installing the motor, pay attention to the connection accuracy between the shaft of the motor and the mechanical parts to avoid eccentricity or looseness. For the controller, it should be installed in a dry and well-ventilated place, and the grounding protection should be done to prevent electrostatic and electrical failures. For example, the grounding resistance of the controller is generally required to be less than 10 ohms.

Electrical connection inspection: After completing the installation of the electrical system, carefully check whether all electrical connections are correct. Use a multimeter and other tools to check the connectivity of the circuit to ensure that there is no short circuit or open circuit. At the same time, check whether the parameters of electrical components are set correctly, such as the rated power of the motor and the speed control parameters of the driver.

Third, debugging and acceptance after installation

Function debugging

No-load debugging: debugging the motion function when the manipulator is not loaded with any load. Check whether each joint of the manipulator can move accurately according to the instruction, including linear motion, rotary motion, etc. During debugging, we should pay attention to observe whether the motion speed and acceleration of the manipulator are stable, and whether there is abnormal vibration or noise. For example, check whether there is jitter when the mechanical arm is rapidly extended and retracted. If there is jitter, it may be caused by improper setting of motor control parameters or inaccurate installation of mechanical parts.

Load debugging: after no-load debugging is normal, gradually increase the load for debugging. Simulate the actual load in injection molding production and check the performance of the manipulator under load. Focus on the bearing capacity, positioning accuracy and repeated positioning accuracy of the manipulator. For example, for an injection manipulator with a rated load of 100 kg, its positioning accuracy should be kept within the design requirements when loading 80 kg, and the general positioning accuracy error can be controlled within 1-3 mm.

Security system debugging

Inspection of safety protection devices: check whether safety protection devices such as safety light curtain, emergency stop button and fence are installed correctly and can work normally. The safety light curtain should be able to accurately detect people or objects entering the dangerous area and stop the movement of the manipulator in time. The emergency stop button should be installed in an easy-to-operate position, and the power supply of the manipulator can be cut off immediately after being pressed. For example, the response time of testing safety light curtain should generally be within tens of milliseconds.

Safety parameter setting: Set reasonable safety parameters in the controller, such as speed limit and torque limit. When the manipulator runs abnormally, such as exceeding the set value of safety parameters, the system should be able to automatically take corresponding safety measures, such as slowing down, stopping or giving an alarm. For example, set the maximum speed limit of the manipulator to prevent safety accidents such as collision caused by too fast speed.

Acceptance criteria and procedures

Formulation of acceptance criteria: according to the technical specifications of the manipulator and the actual needs of users, formulate detailed acceptance criteria. Acceptance criteria should include mechanical performance (such as motion accuracy, bearing capacity, etc.), electrical performance (such as control function, signal transmission, etc.), safety performance and other aspects. For example, the acceptance standard stipulates that the repetitive positioning accuracy of the manipulator should be within 0.5 mm, and the insulation resistance of the electrical system should be greater than 1 megohm.

Acceptance process execution: according to the requirements of acceptance standards, the manipulator is fully accepted. The acceptance process includes data review (such as equipment instructions, installation and debugging records, etc.), appearance inspection, function test, safety test and other links. Only when all the acceptance items meet the standards can the manipulator be confirmed to be qualified and put into use.