How to install and debug the manipulator of injection molding machine according to different types of injection molding machines?

The core of installing and debugging the manipulator of injection molding machine is to "first match the type of injection molding machine with the specifications of manipulator, and then execute it step by step according to" mechanical docking → signal linkage → parameter debugging → trial production optimization ".The key differences of different injection molding machines (vertical/horizontal/two-color/high-speed machine) focus on installation and positioning, picking path and linkage logic. The specific operations are as follows:

First, the core premise: the matching check between injection molding machine and manipulator

Specification matching: according to the clamping force, modulus of tolerance and mold opening stroke of the injection molding machine, choose the manipulator with suitable load (grabbing weight) and stroke (X/Y/Z axis) (such as the horizontal single-arm manipulator for small horizontal machines and the double-arm manipulator for large machines).

Interface matching: confirm that the injection molding machine has manipulator linkage interface (I/O signal interface, air pressure interface). If the old equipment has no standard interface, a signal conversion module needs to be added.

Space matching: Measure the space around the mold after the injection molding machine opens the mold, and ensure that there is no interference in the picking path of the manipulator (the mold, pull rod and safety door do not affect the movement).

Second, the installation and debugging focus of different types of injection molding machines

1. Horizontal injection molding machine (most commonly used, suitable for small and medium-sized plastic parts)

Installation positioning:

The manipulator is fixed at the side of the fixed template of the injection molding machine or at the top of the machine body, and fastened with expansion bolts. The levelness error is less than or equal to ≤0.5mm/m/m to avoid positioning deviation caused by vibration.

Adjust the installation height of the manipulator, so that the sucker/fixture for taking parts is aligned with the center of the mold cavity, and the Z-axis stroke covers the whole path of "taking parts after mold opening → demoulding → blanking".

Linkage debugging:

Signal docking: connect the manipulator's "mold opening completion", "piece taking completion" and "safety door signal" to the I/O port of the injection molding machine, so as to ensure that the manipulator will be triggered after the mold opening of the injection molding machine, and the injection molding machine can be closed only after the manipulator takes the piece.

Path setting: Set the path of "fast approaching → accurate picking → slow demoulding → fast transfer → blanking". After opening the mold, the manipulator quickly extends into the mold with the X axis, and grabs the plastic parts downward with the Z axis to avoid touching the mold core.

Parameter optimization:

Pick-up speed: Adjust according to the weight of plastic parts (X/Y axis speed of light plastic parts is 300-500mm/s, and heavy plastic parts is 150-300mm/s), and the speed of demoulding will be slowed down (≤100mm/s) to prevent plastic parts from falling off.

Fixture parameters: suction-type fixture adjusts negative pressure (-0.6~-0.8MPa), claw-type fixture adjusts clamping force (to avoid clamping plastic parts), and "grab detection" is set (manipulator gives an alarm when plastic parts are not caught, and injection molding machine is out of mold).

2. vertical injection molding machine (suitable for insert molding and small precision parts)

Installation positioning:

The manipulator is fixed at the two sides or the back of the workbench of the injection molding machine, and it is installed in the form of column (to avoid blocking the loading and unloading of the mold), so as to ensure that the Z axis can pick up and down the parts vertically without interference.

Adjust the length of the horizontal arm of the manipulator so that the picking end can cover the die cavity without touching the upper die seat and guide post of the vertical machine.

Linkage debugging:

Signal docking: focus on the "lower die ejection signal" (after the vertical machine ejects the plastic parts, the manipulator will go down to take the parts) to avoid the failure of taking the parts due to the incomplete ejection.

Taking logic: because the mold of the vertical machine is facing upwards, the path of "Z-axis descending → grabbing plastic parts →Z-axis ascending → horizontal transfer → blanking" is set, and the manipulator exits after the ejector rod is reset to prevent collision.

Parameter optimization:

Vertical picking speed: Z-axis descending speed ≤200mm/s to avoid impacting plastic parts; After grabbing, the upward speed can be increased to 300-400mm/s, which improves the efficiency.

Insert adaptation: If insert molding is involved, the linkage of "insert insertion → injection molding → part taking" needs to be debugged synchronously. The manipulator accurately puts the insert into the mold first, and then triggers the injection molding machine to close the mold.

3. Two-color/multi-color injection molding machine (suitable for two-color plastic parts, double molds or rotary molds)

Installation positioning:

Choose double-station or double-arm manipulator to correspond to the two mold cavities of the two-color machine respectively, and ensure that there is no cross interference in the motion paths of the two manipulators during installation.

If it is a rotary die two-color machine, the manipulator is fixed outside the rotating radius of the die to avoid collision during rotation.

Linkage debugging:

Signal docking: Correlate the signal of "First color injection completion → mold rotation → second color taking". After the first arm takes the first color plastic part, the mold rotates, and the second arm puts the insert or directly takes the finished product (according to the process).

Path coordination: Set the action sequence of two manipulators to avoid reaching into the mold area at the same time, and ensure that the manipulators will act again after the rotating mold stops.

Parameter optimization:

Picking sequence: shorten the switching interval between two stations (manipulator action delay ≤0.5s) to match the injection cycle of two-color machine.

Precision control: Two-color plastic parts require higher positioning accuracy (repeated positioning error ≤±0.1mm), so it is necessary to calibrate the positioning accuracy of the X/Y/Z axis of the manipulator to avoid dislocation of the plastic parts during secondary injection.

4. High-speed injection molding machine (suitable for thin-walled parts and high-speed mass production, such as beverage bottle blanks)

Installation positioning:

Choose a high-speed manipulator (response speed ≥500mm/s) and fix it on the top or side of the injection molding machine. When the machine body is connected with the manipulator, an anti-shock pad should be installed to reduce the vibration transmission during high-speed movement.

Optimize the picking path, shorten the stroke (such as using "inclined arm" manipulator), and avoid unnecessary actions taking up the cycle.

Linkage debugging:

Signal docking: High-speed I/O interface is adopted to reduce the signal delay (≤10ms), so as to ensure the synchronous start of the manipulator at the moment of mold opening of the injection molding machine, which meets the requirements of high-speed mass production.

Pick-up logic: Set "synchronous follow-up of mold opening → grabbing → quick demoulding → blanking", and the manipulator moves synchronously with mold opening to shorten the time of picking up parts.

Parameter optimization:

High-speed parameters: the X/Y axis speed can reach 600-800mm/s, and the Z axis speed is 400-600 mm/s. At the same time, the "soft start/soft stop" function is enabled to avoid plastic parts falling off or manipulator impact caused by high-speed movement.

Blanking cooperation: with high-speed conveyor belt, the robot will quickly put the plastic parts into the conveyor belt after picking up the parts, and set up "blanking detection" to ensure the smooth transportation of plastic parts and avoid accumulation.

III. General debugging process (applicable to all types of injection molding machines)

Mechanical calibration:

Manually operate each axis of the manipulator to move, and check whether the travel limit and emergency stop functions are effective, and there is no jamming or abnormal sound.

Calibrate the repeated positioning accuracy (≤±0.1mm) with the laser locator to ensure the consistency of the position of the parts taken.

Signal test:

Test the linkage signals between the injection molding machine and the manipulator (such as mold opening, ejection, part taking and mold closing) separately to ensure accurate signal transmission and no error triggering.

Simulate fault scenarios (such as not getting plastic parts and opening the safety door), test whether the alarm function is normal and whether the injection molding machine stops immediately.

Trial production optimization:

First, test the action of the manipulator with an empty mold, and after confirming that there is no interference, put it into plastic parts for trial production (10-20 molds in a row).

Observe the stability of picking parts (no missing parts, no scratches) and cycle matching degree (manipulator action does not slow down the injection cycle), and fine-tune the speed and positioning parameters according to the trial production results.

Security verification:

Check whether the safety fence and light curtain of the manipulator are effective, and there is no dead angle that people can contact in the movement area.

Verify the "emergency stop" function. After pressing the emergency stop button, the manipulator and injection molding machine stop immediately without inertia movement.

Fourth, the key points for attention

Interference investigation: After all types of injection molding machines are installed, it is necessary to manually run the whole stroke of injection molding machines (mold opening, mold closing and ejection) and the whole path of manipulator, and repeatedly confirm that there is no collision risk.

Air pressure guarantee: the pneumatic fixture of manipulator should ensure the air pressure to be stable (0.5-0.7MPa) and install an oil-water separator to avoid the failure of pneumatic components.

Training and documentation: after debugging, train the operators to clarify the operation process and troubleshooting methods; Keep linkage signal wiring diagram and parameter setting table for subsequent maintenance.