How to customize the suitable manipulator of injection molding machine for automobile parts injection molding manufacturers?

Auto parts injection molding machine manufacturers need to plan the appropriate manipulator of injection molding machine from production requirements, equipment performance, adaptability and other multi-dimensional systems. The following are the specific steps and key points:

First, clear production requirements and scenarios

1. Product characteristics analysis

Product size and weight:

Such as automobile bumper, dashboard and other large parts, the manipulator needs strong load capacity (usually above 50kg) and long arm span (1.5-3 meters); The load of small parts (such as buckles and connectors) can be as low as 5-10kg, and the wingspan can be 0.5-1 meter.

Product structure complexity:

Parts with inverted buttons, multiple cavities or precise structures need special fixtures (such as rotating claws and vacuum suction cups) or high-precision positioning function (repeated positioning accuracy is within ±0.1mm).

Production lead time requirements:

High-speed production (for example, within 10 seconds per mold) requires the manipulator to respond quickly (running speed ≥1m/s), and the driving system adopts servo motor; Pneumatic or variable frequency motor can be selected for medium and low speed production.

2. Parameter matching of injection molding machine

Clamping force and template size;

The mounting base of the manipulator should be adapted to the template size of the injection molding machine (for example, for an injection molding machine with a template width of 600mm, the width of the manipulator base should be ≤550mm), and at the same time, the outrigger should cover the mold opening stroke (for example, the mold opening stroke is 500mm, and the extension length of the manipulator should be ≥600mm).

Workstation layout:

Determine the installation position of the manipulator (vertical/horizontal injection molding machine) and the picking direction (horizontal, vertical or oblique) to avoid interference with other parts of the injection molding machine.

Second, the manipulator type and structure selection

1. According to the number of axes and movement mode.

Type characteristics apply to the cost range of scenarios.

Three axes (XYZ) move horizontally, vertically and linearly back and forth, with simple structure, low cost and repeated positioning accuracy of 0.5 mm.. Small parts picking and simple sorting. 50,000-150,000 yuan

Five axes (XYZ+R1+R2) add wrist rotation (R1) and arm swing (R2), which has high flexibility and can adapt to multi-angle picking. Pick-up and turn-over assembly of complex dies. 150,000 to 300,000 yuan

Six-axis (multi-joint) bionic human arm structure, 6 degrees of freedom, 360 flexible movement, positioning accuracy of 0.1 mm. High-precision assembly and complex trajectory movement. 300,000-800,000 yuan

2. Select by driving mode

Servo drive: high precision, high speed, low noise, suitable for precision parts, but the cost is higher (30%-50% higher than pneumatic).

Pneumatic drive: low cost, simple maintenance, but limited speed and accuracy, suitable for low speed and low load scenes.

Third, the core functions and configuration customization

1. Design of end effector (fixture)

Fixture type:

Vacuum sucker: it is suitable for parts with flat surface (such as door panels and instrument housings), and it is necessary to ensure the air tightness of the workpiece.

Mechanical claw: it is used to grab special-shaped parts or heavy parts, and the claw type (such as claw radian and anti-slip tooth pattern) needs to be customized according to the product contour.

Magnetic clamp: only for metal insert parts, pay attention to the influence of residual magnetic field on products.

Quick-change structure: If a variety of parts are produced, a quick-change jig can be designed (the replacement time is less than or equal to 5 minutes) to improve the flexibility of production line.

2. Detection and safety system

Visual inspection: integrated CCD camera can detect the lack of materials, flash and size deviation of products in real time, and the positioning accuracy is ±0.05mm (such as automobile lens parts).

Sensor protection: infrared light curtain and collision sensor are installed to prevent the manipulator from colliding with molds and personnel, which conforms to ISO safety standards.

3. Automation integration function

Linkage with peripheral equipment: docking conveyor belt, sorter and packaging line to realize the automation of the whole process of "picking-testing-sorting-packing".

Data interface development: protocol interfaces such as OPC UA and Modbus are reserved, connected to the MES system of the factory, and equipment OEE (equipment comprehensive efficiency) is monitored in real time.

Fourth, supplier selection and technology docking

1. Key points of supplier evaluation

Industry experience: priority is given to manufacturers with auto parts cases (such as Toyota, Volkswagen and other supporting robots), and acceptance reports of past projects (such as beat stability and failure rate data) are required.

Customization ability: Capable of 3D modeling (SolidWorks/UG) and simulation analysis (such as motion trajectory simulation and load torque calculation), and can provide detailed scheme design drawings.

2. Technology docking process

Provide parameter list:

Including injection molding machine model (such as Haitian MA600), mold drawings, 3D model of products, and production lead time requirements.

Scheme review:

The supplier shall submit the robot motion simulation video, fixture design drawing and electrical control schematic diagram to confirm the interference risk.

Prototype test:

Conduct 1000 cycle tests in the supplier's factory to verify the success rate (≥99.5%), positioning accuracy, noise (≤75dB) and other indicators.

V. Cost Control and Return on Investment

1. Reference of cost composition

Proportion of core components: servo motor (25%-30%), controller (15%-20%), fixture (10%-15%) and detection system (10%-20%).

Cost-effective strategy:

For non-critical processes (such as picking common parts), three-axis pneumatic manipulator can be selected (cost 50-80 thousand yuan); For precision parts (such as engine sensor housing), a five-axis servo manipulator (150,000-250,000 yuan) is needed to avoid over-configuration.

2. Calculation of ROI (Return on Investment)

Manpower saving: one manipulator can replace 2-3 operators (calculated by annual salary of 80,000 yuan/person, saving 160,000-240,000 yuan annually).

Efficiency improvement: automatic production can reduce the time of manual picking (for example, saving 5 seconds per module) and increase the annual production capacity by 10%-15%.

Return period: usually 1-2 years recoverable cost (depending on the scale of production capacity and labor cost).

VI. Installation and after-sales guarantee

Installation and debugging: the supplier needs to send engineers to debug on site to ensure that the manipulator and the injection molding machine move synchronously (such as taking parts within 0.5 seconds after mold opening), and provide operation training (training duration ≥2 days).

Warranty and maintenance: The warranty period is required to be ≥1 year, and the vulnerable parts (such as cylinders and sealing rings) should be provided with spare stock, and the after-sales response time should be ≤24 hours (emergency failure should be on site within 4 hours).

summary

Customized manipulator of injection molding machine should take "product demand as the core, equipment adaptation as the basis and efficiency improvement as the goal", and realize efficient operation of automatic production line through accurate parameter matching, function customization and supplier screening. It is suggested that manufacturers should first carry out small batch trial production verification (such as trial operation for 3 months), and then purchase in bulk to reduce investment risk.