How to plan the site for installing injection manipulator in automobile injection molding workshop?

Site planning of injection manipulator in automobile injection molding workshop (complete floor-to-floor version)

Focus on five cores: safety, picking path, mold changing space, logistics turnover and later production expansion, taking into account the requirements of large size, high productivity and high safety of automobile parts (door panels, instrument panels, bumpers, interior trims, etc.).

First, determine the overall layout principle.

Arrange the machines in a unified direction.

The priority line is arranged in a straight line, which is convenient for the manipulator to unify the picking direction, share the conveyor belt and patrol the personnel.

Large machines (above 800T) are recommended to be arranged in a single row to avoid double row congestion.

Separation of people flow, logistics and mold flow

Personnel walkway ≥ 1.2m.

Material turnover channel ≥ 1.8 ~ 2.5m.

Mould transport channel ≥3m (crane/forklift)

Reserved safety distance

No fixed obstacles are allowed within the manipulator's activity range.

The equipment spacing is uniform, which is convenient for adding automation, conveyor belt and water and electricity bridge in the later stage.

Second, the single injection molding machine+manipulator core size planning

1. Front and rear space of the machine

Front of injection molding machine (operating side)

Outside the range of manipulator's traverse/arm movement, an operation space of ≥ 1.0 ~ 1.5m shall be reserved.

Large pieces of automobile (bumper/door panel) need to be larger: ≥ 1.8m..

Back of injection molding machine

The reserved electrical space for maintenance and water connection is ≥ 0.8 ~ 1.2m..

Servo manipulator, dryer and hopper shall be ≥ 1.5m..

2. The space above the manipulator (key)

Single-axis/transverse manipulator: top clear height ≥ 3.0 ~ 3.5m.

Five-axis servo manipulator (commonly used for automobile parts): ≥ 3.5 ~ 4.5m.

Above it is forbidden to have air ducts, bridges and fire hoses crossing the picking track to avoid interference.

3. Left-right spacing of the machine

Minicomputer (100 ~ 300 t): spacing ≥ 1.5m.

Medium-sized machine (300 ~ 600 t): spacing ≥ 2.0 ~ 2.5m.

Mainframe (over 600T, automobile structural parts): spacing ≥ 2.8 ~ 3.5m.

Auto parts often need: nozzle cutting+swinging+inspection+packing, and it is very painful to add equipment later when the spacing is small.

Three, pick up and post-processing area planning

Automobile injection parts generally need to be taken → water cut → set the tray/box → check the fixture, and the site should be reserved at one time:

Manipulator falling material level

Below the blanking port, the rubber cutting port workbench/conveyor belt is planned, and the length is determined according to the product:

Small pieces: 1.5 ~ 2m

Door panels/columns: 2.5 ~ 3.5m.

Bumper: over 4m

Pendulum/bin area

1.2m×1.0m empty box+finished product box shall be reserved beside each machine.

Double-layer material rack is recommended for auto parts to save ground.

Inspection fixture and quality inspection position

Every 2 ~ 4 machines shall be provided with a quality inspection platform with a size of 1.5m×1m and a distance of no more than 3m.

Four, safety area planning (mandatory requirements of automobile factory)

Manipulator safety fence

A safety fence/exit door is set at the periphery of the activity range, and the height is ≥ 1.2m..

The safety door is equipped with a door lock switch, which stops when the door is opened.

Danger zone warning

Draw a yellow warning line in the up-and-down and back-and-forth swing area of the manipulator, and no one is allowed to stand.

Emergency stop arrangement

There are emergency stops at the side of the machine, at the entrance of the fence and at the end of the conveyor belt.

Anti-splash and anti-drop

Auto parts are large in size and easy to fall and crack, so it is necessary to make a soft landing and buffer under the blanking area, and enclose the baffle.

Five, water, electricity, gas, network wiring planning

air supply

Two air ports (manipulator+fixture) are reserved for each machine, and the pressure is 0.5 ~ 0.7 MPa, which is dried and filtered.

Power Supply 

The manipulator has an independent power supply circuit, which is not the same as heating and servo to avoid interference.

Bridge roof walking

All the gas pipes and wires should go to the top bridge, and the ground should not be pulled to prevent the forklift from crushing.

Network/signal

Reserved Ethernet port for MES, production counting and abnormal alarm.

VI. Moulds, auxiliary machines and surrounding sites

Die changing space

The front of the machine is reserved with a die placement position and a die changer passage, and the mainframe is recommended to be ≥3m wide.

Dryer/suction machine

Put it behind the machine or on the rack, without occupying the operation surface, and reserve the heat dissipation space.

water coolant

Centralized water supply, the main pipe diameter is enough to avoid insufficient production pressure of multiple machines at the same time.

Seven, automobile injection parts special attention

Large products reserve more swing space.

The manipulator of bumper and door panel has a long stroke, and it is easy to hit the guardrail and conveyor belt, so the trajectory must be simulated in advance.

Consider automatic upgrade redundancy.

At least reserve space for installing conveyor belt, container loader and palletizer, so as to avoid re-disassembly and modification later.

Cleanliness control

Automobile interior parts are sensitive to oil pollution and dust, the ground is made of epoxy, and the material area is closed to reduce the source of dust.

Noise and heat dissipation

Strengthen the ventilation in the area with dense manipulator to avoid alarm shutdown caused by high temperature in summer.

Eight, the simplest site planning checklist (direct control)

Machine spacing meets the requirements of current+post-automation.

Manipulator up and down, left and right without interference.

Take parts → shear nozzle → swing plate streamline is smooth.

Safety fence+safety door is complete.

The ground passage meets the requirements of forklift/crane.

Water, electricity and gas go to the top, and there is no chaos on the ground.

Finished goods box, empty box and waste box are fixed.

Reserved places for quality inspection and fixture placement