What are the steps to install the injection manipulator to pick up the parts in the beverage bottle processing factory?

The process of "pre-preparation → hardware installation → system docking → debugging and optimization → acceptance and confirmation" should be followed to ensure the accurate connection of all links and finally achieve stable picking. The following are the specific steps:

First, preliminary preparation: clear parameters and site planning.

Parameter confirmation and scheme design

Collect core parameters: injection molding machine model (tonnage, mold opening stroke, pull rod spacing), beverage bottle specification (weight, size, material, such as PET bottle blank/HDPE bottle body), production lead time (single-mode cycle), and picking demand (single picking quantity, side posture/overturning required).

Make the installation plan: according to the parameters, determine the manipulator type (such as single-axis or three-axis servo manipulator, gantry type), fixture style (pneumatic gripper/vacuum chuck), installation position (side/top/rear of injection molding machine), and draw the layout (mark the movement track of the manipulator and the safe distance from peripheral equipment ≥50cm).

Site and tool preparation

Pre-treatment of the site: clean up the sundries around the injection molding machine to ensure that the installation ground is flat (if it is fixed on the ground, check the cement strength, bearing capacity ≥ 500 kg/m); If it is installed in the body of injection molding machine, confirm that the connecting holes of the body match.

Tool list: forklift/crane (handling manipulator host), level meter (leveling), expansion bolt (fixing base), wrench (M10-M20 specification), multimeter (circuit detection), marker pen/tape measure (positioning mark).

Second, hardware installation: mechanical structure fixing and component assembly

Manipulator host fixing

Hoisting and positioning: use forklift or crane to move the main machine of manipulator (including vertical column and transverse arm) to the preset position, and adjust the direction according to the layout to ensure that the movement range of transverse arm covers the mold picking area and placing point (such as conveyor belt).

Fixed base:

Ground installation: punch holes in the marked position of the base with an impact drill, implant expansion bolts (specifications ≥M16, depth ≥10cm), and after tightening, calibrate the levelness of the base with a spirit level (error ≤1mm/m) to prevent vibration deviation during operation.

Installation of the machine body: fix the manipulator column with high-strength bolts (matched with locking washers) through the screw holes reserved for the fixed template of the injection machine to ensure that it is perpendicular to the machine body of the injection machine (verticality error ≤0.5mm/m).

Perform component assembly

Install the transverse arm and lifting shaft: connect the transverse arm (including guide rail) with the upright post and tighten the fixing screws; The lifting shaft (which drives the gripper to move up and down) is installed on the sliding block of the horizontal arm. Check whether the sliding is smooth (no jamming or abnormal noise).

Fixture installation: Install the clamping jaw/sucker according to the product design, such as:

Bottle blank taking: install multi-station pneumatic clamping jaws (the number is the same as the number of mold cavities), the spacing of clamping jaws is aligned with the spacing of bottle blanks in the mold, and the material of clamping jaws is silica gel (scratch-proof bottle mouth);

High temperature bottle body: install insulation board (between clamping jaw and lifting shaft), or replace high temperature resistant metal clamping jaw (with buffer spring).

Third, system docking: the circuit is connected to the gas path.

Gas path connection

Air source preparation: connect compressed air (pressure 0.5-0.6MPa), and install a triple piece (filter+pressure reducing valve+oil mist device) in front of the air source interface of the mechanical hand to filter moisture and impurities and provide lubrication for the cylinder.

Pipeline laying: Connect air source → solenoid valve group → gripper cylinder/vacuum generator with air pipe, and the pipeline shall be fixed along the robot arm (tied with a tie to avoid winding during movement), and the joint shall be locked with a clamp (to prevent air leakage).

Test: ventilate manually, and check whether the jaws open and close smoothly, and whether the suction force of vacuum sucker reaches the standard (the adsorbable product will not fall off after hanging for 10 seconds).

Circuit connection

Power supply connection: connect 380V three-phase electricity (manipulator host) and 220V commercial power (control system), install leakage protector (current matching manipulator power), and the grounding resistance is ≤4Ω (to prevent electric shock).

Signal docking: the manipulator control system and the injection molding machine PLC are connected through signal lines, and the core signals include:

Injection molding machine → manipulator: signal of mold opening in place and signal of safety door closing;

Manipulator → injection molding machine: pick-up completion signal and emergency stop signal;

Use a multimeter to detect the on-off of the line to ensure that there is no short circuit or virtual connection.

Fourth, debugging optimization: action calibration and parameter setting

Origin and stroke calibration

Setting the mechanical origin: perform the operation of "returning to the origin" through the manipulator control panel, confirm that the origin position of each axis (traversing, lifting and rotating) is accurate (error ≤0.5mm), and record the coordinate values.

Limit the range of motion: set the soft limit of each axis in the control system (for example, the maximum descending distance of the lifting shaft ≤ the depth of the mold cavity+5mm) to prevent the over-travel from colliding with the mold or injection molding machine.

Picking action debugging

Single-step action test: Manually control the manipulator to complete the single-step action of "descending → gripper closing → ascending → traversing → gripper opening → resetting", and observe whether it is smooth or not, with emphasis on checking:

Pick-up point alignment: after the gripper descends, it is necessary to accurately buckle the bottle mouth (or suck the bottle body), and the deviation is ≤0.5mm (it can be achieved by fine-tuning the gripper position or modifying the coordinates of the control system);

Obstacle avoidance confirmation: avoid the pull rod and safety door of injection molding machine when the horizontal arm moves, and do not touch the parting surface of the mold during lifting.

Automatic cycle test: start the linkage between the injection molding machine and the manipulator, simulate the production cycle, record the picking time (80% or less of the mold opening time of the injection molding machine to avoid affecting the beat), and observe whether the product is stably grabbed (no drop or scratch).

parameter optimization

Speed parameters: adjust the speed of each shaft (for example, when the lifting shaft descends close to the mold, slow down to 100mm/s to avoid impact; The traverse speed is set to 500-1000mm/s according to the beat).

Clamping force parameters: the air pressure of the pneumatic gripper is adjusted by the pressure reducing valve (the air pressure of bottle blank taking is 0.3-0.4MPa), and the vacuum degree of the vacuum sucker is adjusted (≥-0.6bar) to ensure that the product can be grasped stably without damage (check whether there is any indentation on the bottle body and whether the bottle mouth is deformed after trial grasping).

V. Acceptance and Curing: Confirmation of Safety and Standards

Functional acceptance

Continuous operation test: continuous production of 500 modules, check the success rate of taking parts (≥99.5%), the qualified rate of products (no pinch and deformation), and no abnormality of equipment (no abnormal sound, no oil leakage).

Safety acceptance

Protection inspection: the protective fence is firmly installed, the equipment stops immediately when the safety grating is triggered, and the emergency stop button functions normally (the shafts are locked after being pressed).

Operation training: provide training for operators, including start and stop of manipulator, manual operation and fault reset (such as material jam handling), so as to ensure that safety regulations are mastered.

Document curing

Record key parameters: archive the coordinates, speed, clamping force and other parameters of the manipulator and stick them next to the equipment for easy access;

Sign the acceptance sheet: confirm that the installation meets the requirements, and clarify the after-sales maintenance responsibilities (such as the troubleshooting process during the warranty period).

summary

The core of installation is "accurate matching+safety and stability": the manipulator is ensured to adapt to the equipment/product by confirming the parameters in the early stage, the hardware installation pays attention to levelness and fixed strength, the system docking ensures smooth signals, and the action details are repeatedly optimized in the debugging stage, so as to finally achieve the goal of "quick picking, zero damage and high safety" and lay the foundation for the automatic production of the beverage bottle processing factory.