What safety factors should be considered when installing injection manipulator in automobile injection molding workshop?

Here is a complete set of safety factors that must be considered in the automobile injection molding workshop+injection manipulator, which completely conforms to the safety audit and inspection standards of the automobile parts factory and can be directly used for scheme, disclosure and acceptance.

A, mechanical movement safety (the core, the most easy to hurt)

Range of motion isolation

The whole stroke of the manipulator must be free of obstacles, and no personnel are allowed to enter.

Safety guardrail/fence must be set with a height of ≥1.2m to prevent mistaken entry.

Anti-extrusion and anti-shearing

There must be a safe gap between the manipulator and the template, mold and fixture of the injection molding machine.

The movement path of the gripper and fixture cannot form a "pinch point".

Prevent the workpiece/material head from flying out.

Automobile injection-molded parts (door panels, decorative panels, bumpers) are large in size, heavy in weight and easy to splash when broken.

Add a protective baffle/safety cover in the pickup area to prevent products and nozzle materials from flying out and hurting people.

Anti-fall strike

The transverse mechanism, servo arm and fixture installed at high places shall be prevented from loosening and falling off.

The clamp cylinder should be locked with power-off/gas-off to prevent it from falling halfway.

Second, safety control and electrical safety (mandatory grade of automobile factory)

Safety loop level

Meet the safety level above ISO13849 PLd/Cat.3

Emergency stop, emergency door and grating must use dual-channel safety module.

Emergency stop system

At least 3 emergency stops: manipulator body, operation panel of injection molding machine and entrance of safety fence.

Any emergency stop is triggered → the whole system stops immediately and safely, without coasting.

Safety door/safety interlock

Access doors and safety guardrail doors must be equipped with safety door lock switches.

The door is opened → the manipulator is forced to prohibit the action and cannot be started.

Security Grating/Area Scanner

When the operator installs grating at the entrance and exit side, the shielding will be suspended.

Grating protected areas shall not be blocked by objects, and shall not be shielded by short circuit.

Third, the mold, fixture and parts taking process are safe.

The fixture is reliable in clamping.

Vacuum sucker needs negative pressure detection, and it will not be taken when the suction is insufficient.

The pneumatic gripper needs to clamp the confirmation signal, and the transverse movement will not be started without clamping.

Anti-interference mold

The manipulator must interlock signals when it enters the mold to take parts:

Signal of mold opening in place → Allow entry.

The manipulator exits → mold clamping is allowed.

Prevent the manipulator from closing the mold while it is still in the mold, causing major equipment accidents.

Anti-stacking and anti-jamming

When the nozzle and product are stuck, the manipulator can't forcibly pull.

Set overload protection, abnormal position alarm and automatic stop.

Four, gas circuit, circuit, hydraulic safety

Gas source safety

Unstable air pressure will lead to the loosening of the gripper, so it is necessary to stabilize the pressure+filter+oil-water separation.

A check valve/locking valve is added to the cylinder circuit, so that the claw cannot be lost when the air is cut off.

Electrical anti-interference

The power line of the manipulator is wired separately from the servo line and the sensor line.

Reliable grounding, to prevent misoperation, disorderly trajectory.

Anti-leakage and anti-short circuit

The workshop is wet and greasy, and the cable should be wear-resistant and oil-resistant, and it should not be mopped or squeezed.

The control cabinet is dust-proof and oil-proof, with good heat dissipation to avoid high temperature fire.

Five, man-machine operation safety (focusing on operators)

Operation authority management

Automatic mode/manual mode is strictly distinguished, and manual mode is allowed for debugging.

Debugging must use low-speed inching, and high-speed manual operation is prohibited.

Warning sign

Warning signs shall be posted in the dangerous areas of sports: no reaching out, no standing, and attention to pinch injuries.

Draw yellow warning lines in the rotating and lifting areas.

Misstart protection

The start button needs to be started with both hands or with a protective cover to prevent accidental touch.

In debugging mode, mold closing and picking must be confirmed before execution.

Six, maintenance and repair safety (accident-prone links)

Maintenance must cut off power and gas.

Enter the interior of the manipulator for maintenance → LOTO.

Turn off the main power supply and main air supply, and release the residual air pressure.

Anti-accidental clamping

When debugging the mold, the safety bolt must be inserted, and it is forbidden to rely on electrical signals.

Adequate maintenance space

The inside of the guardrail shall be reserved with an overhaul space of ≥0.8m, which is not crowded or climbed.

Seven, the special additional safety risks of automobile injection molding workshop.

Anti-dumping and anti-smashing of bulky products

Bumpers and door panels should be placed stably after being taken, and a buffer table should be added.

Shear splash of nozzle material

Add a protective cover to the cutting area to prevent debris from bouncing into the eyes.

Complex workshop logistics

Forklift trucks and turnover trucks are frequent, and the manipulator area does not cross the logistics channel.

High temperature and flame retardant

The barrel of injection molding machine is high temperature, and the manipulator cable should be temperature-resistant, oil-resistant and flame-retardant.

Eight, the simplest safety acceptance formula

The guardrail is fully enclosed, the grating is in place, the emergency stop is complete, and the interlock is effective.

Gas-cut locking, interlocking mold clamping, mode switching and maintenance locking.

No interference, no splash, no random wiring, no blind spots.