Introduce in detail: Installation and debugging process of injection molding manipulator?

Installation and debugging process of injection molding manipulator

The installation and debugging of injection molding manipulator is the core link to ensure its coordinated and stable operation with the injection molding machine and realize automatic production. It needs to follow the standardized process of "preliminary preparation → mechanical installation → electrical connection → system debugging → linkage trial operation → acceptance and delivery", and each stage has strict technical requirements and safety specifications, as follows:

First, the preparatory stage

Verification of site and foundation conditions

First of all, it is necessary to confirm the installation space around the injection molding machine, ensure that there are no obstacles in the installation position and arm span of the manipulator, and reserve a maintenance channel of ≥80cm. Check the power supply conditions of the workshop. The power supply of the manipulator is usually three-phase 380V/50Hz and the control power supply is single-phase 220V V. It is necessary to ensure that the current carrying capacity of the power supply line matches the total power of the equipment and the grounding system meets the standard (grounding resistance ≤4Ω). In addition, it is necessary to prepare a compressed air source in advance (the pressure is stable at 0.5-0.7MPa, and the air source is dry and oil-free) to provide power for pneumatic components such as the gripper and vacuum sucker of the manipulator.

Inventory of equipment and accessories

Upon arrival, the manipulator body, control cabinet, end effector (fixture/sucker), mounting bracket, cable, instructions and accessories shall be counted one by one according to the packing list, and the appearance of the equipment shall be checked for transportation damage, and the key components (such as servo motor, guide rail and reducer) shall be in good condition. At the same time, the supporting software and firmware versions shall be confirmed to match the equipment model.

Confirmation of technical scheme

Technicians need to reconfirm the installation mode of the manipulator (such as side-hanging, overhead and floor-standing) according to the model of injection molding machine, mold size and product picking path, and make clear the picking rhythm, action flow and safety protection scope to avoid the conflict between subsequent installation and on-site working conditions.

Second, the mechanical installation stage

Mounting base fixing

According to the different installation methods, fix the installation base of the manipulator first. The side-hanging manipulator needs to fasten the bracket on the template or body of the injection molding machine through high-strength bolts to ensure that the verticality deviation between the bracket and the body of the injection molding machine is ≤ 0.5 mm/m; The overhead manipulator needs to be installed on the beam at the top of the injection molding machine, while the floor manipulator needs to pour the concrete foundation and embed the anchor bolts to ensure the bearing capacity and stability of the base and prevent it from shaking during operation.

Manipulator body assembly

First, the main structures of the manipulator, such as columns and beams, are hoisted, and the parallelism and verticality of each axis are calibrated by laser levels. Then, the guide rails, screw rods and servo motors of X-axis, Y-axis and Z-axis are installed in turn to ensure the uniform meshing clearance of transmission parts. When assembling the end effector, it is necessary to select a suitable fixture or vacuum sucker according to the size and material of the product, fix it at the end of the manipulator through the flange, and adjust the opening and closing stroke of the fixture or the vacuum pressure of the sucker to ensure the stability of grasping the product.

Installation of limiting and protective devices

Install mechanical limit blocks and photoelectric limit switches at the limit position of the manipulator to prevent equipment damage caused by over-travel operation; At the same time, a safety fence and a grating sensor are installed in the cooperative area between the manipulator and the injection molding machine, so as to prevent people from entering by mistake or equipment from interfering.

Third, the electrical connection stage

The main circuit is connected with the control circuit.

Connect the power cable by a professional electrician, connect the power end of the manipulator control cabinet with the power distribution cabinet in the factory, and do a good job in insulation protection and identification of the cable; Then connect the control cable, and connect the servo driver, encoder, sensor and other components of the manipulator with the PLC and touch screen in the control cabinet to ensure that the shielding layer of the signal line is well grounded and prevent electromagnetic interference.

Signal docking with injection molding machine

This is the key to realize cooperative operation. It is necessary to connect the mold opening and closing signals and ejector pin advancing and retreating signals of the injection molding machine to the manipulator control cabinet, and at the same time feed back the picking completion signal and standby signal of the manipulator to the injection molding machine to realize the linkage of the two actions. For example, after the injection molding machine opens the mold in place, it sends a signal to the manipulator, and the manipulator can start the picking action; The manipulator sends a signal after picking up the parts, and the injection molding machine can close the mold and start the next mold production.

Pneumatic system connection

Connect the air supply pipeline to the pneumatic solenoid valve group of the manipulator, install the pressure gauge and filter, debug the pressure and response speed of each pneumatic component, ensure the accurate and stable action of clamp opening and closing and suction cup adsorption, and check that there is no air leakage in the pipeline.

Fourth, the system debugging stage

Parameter initialization and single shaft debugging

After the power supply is turned on, the parameters are initialized in the touch screen of the control cabinet, and the basic data such as the shaft type, stroke range and servo motor parameters of the manipulator are set. Then debug the single shaft, and control the X, Y, Z and the rotating shaft (if it is a multi-shaft model) by inching, check whether the running speed and acceleration of each shaft are normal, confirm that there is no jamming or abnormal sound, and calibrate the zero position and repeated positioning accuracy of each shaft (usually ≤±0.1mm).

End effector debugging

Test the opening force and response time of the fixture, and reduce the fixture pressure for fragile or high-precision products to prevent the product from being pinched; Test the adsorption force of vacuum sucker, and adjust the time sequence of adsorption and release through vacuum pressure gauge and time relay to avoid product falling or residue.

Action program writing and debugging

According to the requirements of production technology, the action program of picking, transporting and placing is written in PLC, and the motion trajectory and takt time of each axis are set. For example, for multi-cavity mold, write a program to grab multiple products synchronously; For the products that need to separate the nozzle, the program of cutting the nozzle with scissors after grabbing is written. When debugging, run at low speed first, gradually optimize the action path, reduce the idle travel time and improve the production rhythm.

Five, linkage trial operation stage

No-load linkage test

First, carry out the no-load linkage between the manipulator and the injection molding machine, simulate the whole production process, check whether the signal interaction between them is smooth and whether the action sequence matches, and mainly verify whether there is no delay or interference in the connection of mold opening, part taking and mold closing, and at the same time test the effectiveness of safety functions such as emergency stop button and fault alarm.

On-load commissioning

Load the injection mold and start the injection molding machine, carry out the linkage trial operation of the belt product, observe the stability of the product grasped by the manipulator and the accuracy of the placement position, and check whether the product has scratches, deformation and other problems. Keep running for 2-4 hours, record the operation parameters and faults of the equipment, and adjust the servo parameters, fixture position or action sequence in view of the problems such as jamming and unstable pickup.

Beat optimization

According to the trial operation data, the running speed and action connection of each shaft are optimized, and the cycle time of single picking is shortened and the overall production efficiency is improved on the premise of ensuring safety and product quality. For example, adjust the descending and ascending speed of the manipulator to match the mold opening speed of the injection molding machine; Optimize the path of product placement and reduce unnecessary rotation or translation.

VI. Acceptance and Delivery Stage

Performance index detection

According to the equipment technical agreement, the core indexes such as repetitive positioning accuracy, load capacity and running rhythm of the manipulator are tested, and whether the functions such as safety protection and fault alarm are up to standard are also checked. The technicians and customers will jointly confirm the test results.

Operation and maintenance training

Explain the operation process, parameter setting method, daily maintenance points and common troubleshooting skills of the manipulator to the customer's operators and maintenance personnel, and provide operation manuals and maintenance ledgers to ensure that relevant personnel can independently complete the equipment operation and basic maintenance.

Delivery and data archiving

Arrange installation and debugging records, test reports, electrical drawings and other materials, hand them over to customers and go through the acceptance procedures, and at the same time clarify the warranty period and after-sales service terms of the equipment to complete the overall delivery.