How to debug the injection manipulator installed in the injection workshop of toy factory?

Here's a brief introduction to you: the complete debugging process of the injection molding workshop of toy factory-injection molding manipulator after installation (from empty machine to mass production, follow it directly on site) is suitable for small tonnage injection molding machine (50-300T)+ small servo/pneumatic manipulator (single axis/three axis/five axis).

First, preparation before commissioning (safety+foundation confirmation)

1. Safety conditions (must be met first)

The injection molding machine is powered off, the mold is fully locked, the shooting seat retreats, the mold is opened, and there is no foreign matter.

The manipulator is fixed horizontally, and the anchor/bracket is locked; Safety door, fence and grating are installed in place and normal.

The emergency stop button (manipulator+injection molding machine) is sensitive and effective, and the two machines are connected in series.

Power supply and gas source: the voltage is stable 5%, the air pressure is 0.5–0.7 MPa, and there is no air leakage.

2. Mechanical and hardware inspection

The manipulator is fixed firmly, without inclination and shaking; Arm/beam level.

Fixture/suction cup: it is suitable for toy products (small parts/thin walls/multi-cavities), the suction cup is not damaged, the trachea is not bent, and the fixture can be opened and closed smoothly without jamming.

Connection: The communication line (IO/24V) between the manipulator and the injection molding machine is connected correctly, and there is no wrong connection (emphasis: mold opening, mold locking permission, and safety door signal).

3. Program and parameter initialization

Start the machine and enter the manual/origin mode, and return to the origin (X/Y/Z/A/C axis) to confirm that all axes return to zero normally without alarm.

The manipulator parameters are restored to the factory default, or the corresponding model template is imported; Close all automatic interlocks, and debug manually first.

Second, manual debugging (single axis action+safety limit, the most critical)

1. Single-axis manual operation (low speed! Slow down! )

X-axis (front and back): move forward/backward at low speed, and check that there is no jam, no abnormal sound and the limit switch is effective; The stroke covers the center of the mold+picking+placing position.

Y-axis (up and down): low-speed lifting, confirm the up and down limit and the buffer is normal; The lowest drop point is 20–50 mm higher than the die, and the anti-collision die.

Z-axis (left/right/rotation): the movement/rotation is stable, without jitter and jamming; Multi-cavity toys should be aligned with each acupoint.

Fixture/suction cup: manual opening/closing, simple action, no air leakage and firm clamping; Vacuum sucker for thin-walled toys+low pressure, anti-pinch.

2. Safety limit and interference zone setting

Hard limit: stop the machine immediately when the positive and negative limits of each shaft are in place, and it cannot be dismantled or shorted.

Soft limit: set a safe boundary, and the manipulator shall not enter directly above the mold (mold locking area) to prevent mold collision.

Interference zone: interlock the injection molding machine with the manipulator;

The safety door of injection molding machine is not closed → the manipulator is forbidden to enter the mold.

The manipulator is in the mold → the injection molding machine is prohibited from locking the mold.

3. Manual teaching of in-mold picking position

The injection molding machine opens the mold in place and stops at the position where the mold is opened.

Manually move the manipulator to the center of the mold, directly above the product (the Y axis drops to 5–10 mm above the product).

Fine-tune X/Y/Z to align the sucker/fixture with the product (multiple cavities are aligned one by one).

Lower the contact product, inhale/pinch it, and confirm that it is firmly sucked/clamped without deviation.

Ascending → retreating → rotating, moving out of the mold cavity, without collision or scraping.

Save the pickup point (P01) and the in-mold safety point (P00).

4. Put/pendulum position teaching

Move the manipulator to the top of the assembly line/turnover box/tray rack, and adjust the height and level, so that the product can be put down lightly without falling or bumping.

Multi-cavity products are placed in order, and multiple placement points are taught (P02/P03…).

Save the drop point and intermediate transition point to ensure the shortest path and no collision.

Third, linkage debugging with injection molding machine (IO signal+interlock)

1. Communication signal docking (core, to prevent plane collision)

Eight key signals that must be confirmed (24V DC):

Injection molding machine → manipulator: mold opening is finished (OK)

Injection molding machine → manipulator: the safety door is closed

Manipulator → Injection Molding Machine: Pick-up completed (mold locking allowed)

Manipulator → injection molding machine: There is no manipulator in the mold.

Both sides: emergency stop signal (interlock)

Both sides: alarm signal

Manipulator → conveyor belt: loading is completed.

Injection molding machine → manipulator: ejector pin retreat (small parts are protected from top injury)

2. Linkage manual test (step by step)

Injection molding machine opens the mold → the signal is triggered after opening the mold → the manipulator starts to enter the mold.

The manipulator descends → sucks/clamps the parts → rises → exits the mold cavity → sends the signal of "taking the parts complete".

The injection molding machine receives the signal → allows the mold to be locked → at the same time, the manipulator releases the parts.

There is no signal loss, no delay and no error trigger in the whole process; Stop the machine and check the line immediately if the signal is abnormal.

3. Test run in automatic mode (empty mold → material head → product)

(1) Empty mold automatic (no product, running path)

Set single-cycle automatic, and run at low speed (50% speed) for 10–20 times:

The path has no collision, deviation and jitter.

The repeatability of picking/placing position is ≤±0.5mm (toys are enough).

The signal interlock is 100% reliable and has no error.

(2) Try to take the material head (take the waste first, and prevent damage to the mould)

The discharging head is in the mold, and the discharging head is automatically taken → the waste box is placed for 20 consecutive times:

Fixture/sucker can grab stably without dropping.

There is no residue or scratch in the mold.

(3) Product Trial (with products officially)

Injection molding 1 mold product, automatically taking parts → putting parts, 50 times in a row;

The product has no deformation, pinch and scratch (the key to the appearance of the toy).

The success rate of picking parts is ≥99%, and the rate of dropping parts is < 1%.

The cycle time is stable and does not affect the injection cycle.

Fourth, fine optimization of parameters (toy factory focus: appearance+efficiency)

1. Speed/acceleration (to prevent the product from bumping)

In-mold: low speed (30%–50%) and low acceleration (to prevent mold scraping and product falling off).

Air: Medium speed (70%-80%), steady and not shaking.

Release: Very low speed (20%-30%), light release with anti-collision appearance.

2. Suction cup/fixture parameters

Vacuum sucker: suction-0.06~-0.08MPa (thin-walled toys are too big to prevent concave absorption); Blowing off, anti-sticking die.

Pneumatic fixture: the pressure is 0.3-0.5MPa, the clamping force is adjustable, and the soft rubber pad prevents the clamping marks.

3. Delay setting (to avoid signal grabbing/dropping)

After the mold is opened → the manipulator enters: the delay is 0.2-0.5s (when the mold is stable).

Suction/clamping: keep it for 0.3-0.5s (to ensure a firm grip).

Put the parts → disconnect the sucker/loosen the fixture: delay 0.2s (put them in place lightly).

V. Acceptance before mass production (continuous stability+safety)

Continuous 100-mode automatic: no alarm, no collision, no missing parts and no defective products.

Cycle matching: the manipulator does not drag the injection hind leg, and the overall cycle is less than or equal to the original manual picking time.

Safety review: emergency stop, interlock, limit and protection are all effective, and there is no safety blind area.

Staff training: 2-3 operators can master manual operation, automatic start-stop and simple fault reset.

Six, common problems and quick treatment (toy factory high frequency)

Parts are taken and dropped: air leakage/insufficient suction of suction cup, loose fixture, off-position → check air pipe, adjust suction and re-teach.

Product pinch/suction: the clamping force is large, the suction force is large, and the part is impacted → depressurized, the suction force is reduced, and the speed of the part is slowed down.

Die bump/die scraping: soft limit error, path interference, signal inversion → reset limit, correct path and check IO line.

Jitter/abnormal sound: unstable fixation, dirty guide rail and high speed → fasten bracket, clean guide rail and slow down.