What are the daily operation specifications of the three-axis injection molding automatic manipulator?

Standard for daily use and operation of three-axis injection molding automatic manipulator

The core follows the principle of * * "special person to operate, start and stop according to regulations, accurately adjust parameters, prevent collision and overload, and conduct spot check before and after work", and formulates specifications around six core links: preparation before starting, starting operation, normal production, mold and production change, shutdown operation and emergency treatment, and at the same time, clarifies operation taboos, avoids equipment damage and production accidents caused by misoperation, and ensures the stability and service life of linkage between manipulator and injection molding machine.

First, the preparation specification before starting (must be done to avoid starting with failure)

Special person for operation: Only trained and qualified operators are allowed to operate. Non-designated personnel are forbidden to touch the operation panel and manually pull the manipulator shaft.

Spot check of environment and appearance: clean up plastic scraps, oil stains and dust on the surface of manipulator, three-axis guide rail and fixture; Check that the fuselage has no bump deformation, the shield and dust scraper are not damaged, the towing chain is not stuck, and the cable/gas pipe is not entangled, worn or dropped.

Spot check of core components:

Pneumatic system: check whether the air pressure of the air compressor is within the rated range of 0.5~0.7MPa, the oil-water separator is free of accumulated water (drained in time), the pressure regulating valve and solenoid valve are free of air leakage, and the negative pressure of the vacuum generator is normal;

Transmission parts: check that the guide rail and screw rod have sufficient grease, no dry grinding and sludge accumulation, and the shaft body moves smoothly by hand without jamming;

End fixture: check that the sucker is not damaged or aged, the clamping force of the gripper is normal, the cutter head of the pneumatic scissors is not cracked, and the fixture fixing bolt is not loose.

Safety and linkage inspection: check that the emergency stop button (machine body+operation panel) is reset normally, and the safety door and fence are not damaged; Confirm that the linkage signal between injection molding machine and manipulator is normal, and there is no signal alarm.

Second, the boot operation specification (step by step to avoid startup shock)

Power-on sequence: start the injection molding machine first → then start the manipulator control system, and reverse power-on is prohibited; After turning on the power of the manipulator, wait for the system self-check to be completed (no fault code, three-axis homing indicator light is on), and then proceed with the subsequent operation.

Manual return to zero: select * * "Manual Mode" on the operation panel, adjust the speed to low gear (≤20% rated speed) * *, and operate three axes (X/Z/Y) to return to mechanical zero one by one, to confirm that the return to zero is accurate and without deviation, and it is forbidden to switch the automatic mode directly without returning to zero.

No-load trial run: In manual mode, inching the three-axis full-stroke operation for 2-3 times, and checking that there is no jamming, abnormal sound, no jig shaking and the suction cup/gripper moves normally; Start the vacuum/pneumatic system, and test that the vacuum detection and gripper limit signal are normal.

Linkage test: In the manual mode, trigger the mold opening signal of the injection molding machine to check whether the manipulator accurately responds to the picking action, and there is no risk of interference with the mold and the mold table. Only after it is confirmed that it is correct can it switch to the "automatic mode".

Three, the normal production operation standard (the core link, to ensure stable operation)

Mode and speed: automatic mode is locked during normal production, and manual mode is forbidden to be switched at will; The running speed is set according to the mold opening rhythm of the injection molding machine, and it is forbidden to run at an excessive fixed speed. If it is necessary to adjust the speed, it should be fine-tuned gradually to avoid sudden acceleration/deceleration.

Load and taking parts: take parts strictly according to the rated load, and overload (including product+fixture+nozzle material) is prohibited; Observe the action of taking parts to ensure that the fixture takes parts stably, without product falling or scratching, and keep a safe distance from the mold after taking parts, without collision risk.

Real-time monitoring: regular inspection in the production process, focusing on:

Three-axis operation is smooth without jitter and abnormal noise, dragging chain is free from jamming and cable is free from pulling;

The pneumatic system has no air leakage, the vacuum negative pressure is stable, and there is no phenomenon of leakage and empty suction;

The linkage signal is synchronized, and the injection molding machine can only close the mold after the manipulator takes the parts, and there is no movement synchronization;

The temperature rise of the equipment is normal, the servo motor and driver are free from overheating and abnormal noise, and the fan of the electric cabinet is running normally.

Exception handling: In case of slight exception in production (such as slight deviation of products and slight air leakage of suction cups), it is necessary to stop the manipulator first (press the "pause" button instead of emergency stop) before handling; It is forbidden to continue production with abnormalities to avoid the expansion of minor faults.

Iv. Operating specifications for mold changing/production changing (accurately adjust parameters to avoid collision with the core)

Stop and lock: Before changing the mold, switch the manipulator to manual mode. After the three axes return to zero, press the "pause" key to turn off the pneumatic/vacuum system of the manipulator, and disconnect the linkage signal between the manipulator and the injection molding machine to prevent misoperation.

Fixture replacement: replace the fixture adapted to the new product, ensure firm fixation, tighten bolts and do anti-loosening treatment; Debug the position and clamping force of suction cups/jaws, match the picking point of new products, and prohibit the jig from shifting its center of gravity and exceeding its weight.

Parameter reset: reset the three-axis (X/Z/Y) stroke, picking position and placing position in manual mode and low gear, and fine-tune the test point by point to ensure that the whole stroke does not interfere with the new mold and die table; Reset vacuum delay and jaw opening and closing time to match the new production beat.

Trial production verification: after the parameter setting is completed, try to take the parts for 3~5 times in manual mode to confirm the accuracy; Switch to automatic mode, run the no-load linkage injection molding machine for 2~3 cycles, and then carry out trial production with materials. After the trial production is qualified, normal production can be resumed.

Five, stop operation specification (step by step, completes the equipment protection)

Routine shutdown (shift change/normal shutdown)

Stop sequence: first stop the automatic mode of the manipulator → three-axis return to zero → turn off the pneumatic/vacuum system → turn off the power supply of the manipulator → finally pay attention to the molding machine, and it is forbidden to directly cut off the power and stop the machine.

Cleaning and finishing: clean up the scraps and oil stains on the surface of the manipulator, the guide rail and the screw rod, wipe the glue and stains on the fixture, and provide anti-aging protection (such as protective sleeves) for the suction cups and clamping claws.

Protective treatment: after turning off the power supply, check that the emergency stop button is reset and the safety door is closed; If the shutdown time exceeds 8 hours, it is necessary to add a small amount of grease to the guide rail and screw rod for dust protection.

Temporary shutdown (short shutdown/inspection)

Press the "Pause" key to return the three axes of the manipulator to a safe position (away from the mold and die table), and it is forbidden to park the manipulator in the mold or in a dangerous position at high altitude;

Keep the power on. If the production is stopped for more than 30 minutes, turn off the pneumatic/vacuum system to avoid the air compressor running at no load.

Six, emergency treatment standard (emergency, give priority to ensure safety)

Emergency stop trigger: In case of collision risk, product sticking, abnormal noise/jitter of equipment, personal danger and other emergencies, immediately press the nearest emergency stop button (fuselage/operation panel/injection molding machine), and no delay is allowed.

Post-emergency treatment:

Disconnect the power supply of the manipulator, investigate the causes of the failure (such as parameter deviation, loose fixture, signal failure, and component damage), and prohibit direct reset and emergency stop without troubleshooting;

After troubleshooting, reset the emergency stop button first, and then power on, reset to zero and start-up step by step according to the "startup operation specification", and resume production after confirming that there is no problem.

Fault alarm: When a fault code appears in the system, the production shall be suspended immediately, and the fault shall be investigated according to the operation manual. If it cannot be solved by itself, the equipment maintenance personnel shall be contacted in time, and forced elimination of the fault code and production with fault are prohibited.

Power failure treatment: In case of sudden power failure, wait for the power supply to be restored, re-power on, return to zero and start-up according to the startup specifications, and then resume production after confirming that there is no deviation.

Seven, operation taboo (strictly prohibited, to avoid equipment damage/accident)

Non-professionals are prohibited from operating, programming or modifying equipment parameters (such as speed, load and travel), and the modified parameters shall be recorded and verified.

Overload and overspeed operation are prohibited, and it is forbidden to raise the speed of servo motor and the pressure of pneumatic system at will.

It is forbidden to manually pull the shaft body and touch the fixture in the automatic mode, and it is forbidden to clean the mold and touch the picking area when the manipulator is running.

It is forbidden to switch the automatic mode directly without returning to zero and no-load test run, and it is forbidden to produce directly without re-adjusting parameters after changing the mold.

It is forbidden to replace the normal pause button with the emergency stop button, and it is forbidden to trigger the emergency stop frequently to avoid the transmission parts and electrical components from being damaged by impact.

It is forbidden to add non-special grease to the guide rail and screw rod, and it is forbidden to disassemble the equipment shield, dust prevention device and safety sensor at will.

It is forbidden to use the manipulator as a handling tool, to add extra weights to the fixture, and to modify the shaft limit and safety protection device.

VIII. Additional Requirements for Daily Operation

Operators should keep running records, and record the startup time, production quantity, equipment abnormality and handling conditions, so as to facilitate subsequent traceability.

During the shift change, it is necessary to hand over the running status of the equipment, the slight anomalies and precautions that have not been handled face to face, and it is forbidden to change shifts without handover.

If there is dust, oil pollution and high temperature in the production environment, it should be cleaned in time to keep the equipment clean and avoid the failure of protective devices.