How to install and debug the five-axis injection molding manipulator?

The installation and debugging of the five-axis injection molding manipulator should follow the process of "hardware positioning first, then system connection, and finally function verification". The core is to ensure accurate mechanical structure, smooth electrical signals and actions in line with injection molding production logic.

First, preparation before installation: laying the foundation

The preparation before installation directly affects the subsequent accuracy, and the following three points should be paid attention to:

Inspection of site and equipment: make sure that enough space is reserved around the injection molding machine, and the ground flatness error is not more than ±2mm (to avoid vibration when the manipulator is running); At the same time, check whether the manipulator body, control cabinet, sucker/gripper and other accessories are complete and the appearance is free from transportation damage.

Tools and data preparation: prepare tools such as torque wrench, level meter, multimeter and insulation tester; Be familiar with the manipulator installation manual and electrical schematic diagram in advance, and make clear the definition of each interface (power supply, signal and gas source).

Safety protection setting: set warning signs in the installation area to cut off the main power supply and air supply of the injection molding machine and the manipulator to avoid safety accidents caused by misoperation.

Second, the core installation steps: accurate positioning and connection

The installation stage should be promoted in three steps: "mechanical fixation → electrical connection → air source deployment" to ensure the coordination of all components:

Fixing the mechanical body: align the manipulator base with the injection molding machine template (or ground embedded bracket) and fasten it with high-strength bolts; Adjust the level of the base with a spirit level to ensure that the X/Y/Z axis guide rail is parallel to the mold opening and closing direction of the injection molding machine, and the bolts are locked with torque as required by the manual (usually 35-50 nm).

Electrical system connection: firstly, connect the main power supply (it needs to match the rated voltage of the manipulator, such as 380V three-phase), and then connect the manipulator control cabinet with the PLC of the injection molding machine through special communication lines (such as RS485 and Profinet) to realize signal interaction (such as opening and closing the mold in place and the manipulator picking up the signal); Finally, connect control lines such as emergency stop and operation panel, and fix the wiring harness with insulating tape to avoid interference.

Installation of air source and end effector: connect the compressed air pipe to the mechanical hand air source interface, adjust the pressure to 0.5-0.7MPa, and check whether there is any air leakage at each air path connector; According to the shape of the product, install suction cups or clamping jaws, and adjust the angle of the end effector to ensure that it can be accurately aligned with the cavity of the injection molding machine.

Third, the debugging stage: from uniaxial to linkage verification

Debugging should follow the logic of "first single-axis inching, then manual operation, and finally automatic circulation", and verify the function step by step:

Parameter initialization and single-axis debugging: turn on the power supply of the control cabinet, enter the manipulator system interface, and reset the basic parameters (such as travel limit, upper speed limit and acceleration of each axis) after restoring the factory parameters; Control the movement of X/Y/Z/A/B axis independently through the "inching mode" of the operation panel, and check whether each axis runs smoothly, without jamming or abnormal sound, and whether the stroke meets the set value.

Manual teaching and path planning: switch to "manual teaching mode", manually control the manipulator to move to key points (such as "standby position → picking position → placing position → origin"), and record the coordinates of each point; Adjust the speed of each axis (initially set to 30% of the rated speed), optimize the path, and avoid the collision between the manipulator and the injection molding machine and peripheral equipment.

Signal interaction and automatic debugging: trigger the mold opening and closing signal of injection molding machine, check whether the manipulator can accurately receive the "mold opening in place" signal and start the picking action; Simulate the automatic production cycle, observe the consistency of picking and placing parts by the manipulator, and verify whether there is missing parts and position deviation (the deviation should be controlled within ±0.1mm); If there is deviation, it can be corrected by fine-tuning the teaching points or modifying the servo parameters.

Safety and performance test: test the effectiveness of emergency stop button and safety light curtain (the manipulator needs to stop immediately after triggering); Run continuously for 30-50 cycles, check whether the motor temperature and gas path pressure are stable, and gradually increase the running speed to the rated value after confirming that there is no abnormality.

Iv. acceptance after commissioning: to ensure compliance with production requirements.

After commissioning, acceptance is required to confirm that it meets the actual production requirements:

Accuracy verification: use a dial indicator to measure the repetitive positioning accuracy of the manipulator, and the repetitive positioning error of the five-axis manipulator should be ≤±0.05mm to ensure that the parts are taken and put in the same position.

Production suitability inspection: combined with the actual injection molding products, verify whether the picking speed and putting efficiency of the manipulator match the cycle of the injection molding machine (usually the action time of the manipulator needs to be shorter than the cooling time of injection molding); Check the grasping stability of the end effector to the product, without scratches or deformation.

Documentation and training: arrange installation and debugging records (such as parameter setting table and teaching point bitmap) and deliver them to operators; At the same time, practical training is carried out to ensure that they master the basic methods of manual control, parameter adjustment and troubleshooting.