What should the injection manipulator pay attention to when it is used to process and pick up plastic pallets?

The plastic pallet is a large, heavy and easily deformed plastic part. When picking up the parts with an injection manipulator, the core is to prevent falling, deformation, anti-collision and safety. The key points for attention are as follows: before starting, during picking, parameters and fixtures, safety and maintenance.

First, check before starting (to prevent hidden dangers)

Load and travel confirmation

Total weight of tray+fixture+nozzle ≤ 2/3 of the rated load of manipulator (safety factor ≥1.5).

Drawing stroke > mold opening stroke+tray thickness; Z-axis stroke ensures that the parts are completely separated from the mold after being taken.

Equipment and safety inspection

The fixing bolt is not loose, and the levelness is ≤ 0.5 mm/m; Emergency stop, safety door interlock and limit switch are sensitive and reliable.

The air source pressure is 0.5–0.7 MPa, and there is no air leakage; The negative pressure of the vacuum system is stable at -0.6~-0.8MPa.

Fixture adaptation

Priority is given to multi-point vacuum sucker+auxiliary gripper: the sucker is made of large-diameter silica gel (scratch-proof and anti-slip), and the gripper is padded with wear rubber.

The clamping point is selected at the rib/thick wall of the tray to avoid thin glue and edges to prevent deformation.

Second, take the process control (anti-dropping, anti-deformation, anti-collision module)

Action rhythm and speed

Downward movement in the mold: high speed → decelerate to ≤ 100mm/s within 100 mm of approaching the mold to avoid impacting the mold and the tray.

Pick-up stop: Stop for 50–100ms after suction/clamping of the suction cup is closed, so as to ensure complete suction/clamping before lifting.

Ascending/traversing: the speed is 150–300 mm/s (heavy parts), the acceleration and deceleration are gentle, and it is forbidden to start and stop suddenly to prevent falling.

Waiting outside the mold: keep a safe distance of ≥50mm from the mold after taking the parts, and make sure that there is no hanging mold to cross again.

Linkage with injection molding machine

Must be connected to the mold opening, parts taking and safety door signal interlocking: the manipulator enters the mold only after the mold opening is in place; The injection molding machine will not close the mold until the parts are taken.

Push-pin matching: The height of push-out of the push-out pin should be that the tray is loose and does not fall off, so as to avoid top crack or die sticking.

Exception immediate handling

Drop/suction deviation: Stop immediately, check whether the suction cup is blocked, leaking or the gripper is loose, adjust the position and pressure and try again.

Sticking to the mold: it is forbidden to pull by force. After suspension, it should be assisted by release agent. If necessary, it should be handled manually to prevent mold damage.

Abnormal sound/jitter: Stop the machine to check for fixation, overload or interference, and then run it after troubleshooting.

Third, the parameters and fixture optimization (stable parts, deformation prevention)

Speed and buffer parameters

The traversing/pulling/lifting speed is set to 70%-80%, and the heavy parts are set to 50%-60%.

The acceleration and deceleration time is prolonged (such as 0.5→1.0s) to reduce jitter and deformation.

Grab parameter

Vacuum sucker: negative pressure is about-0.7MPa, and multiple points are evenly adsorbed to prevent local depression.

Clamping jaw: the clamping force is moderate (based on not crushing the ribs), which can be adjusted by air pressure.

Path optimization

The trajectory should avoid the protruding parts such as the inclined guide pillar and ejector pin plate of the mold, and leave a safety gap of ≥ 20 mm..

The feeding position is flat to avoid the tray cracking caused by the impact of free fall.

Four, safety and daily maintenance (accident prevention, life)

Safety red line

It is forbidden to reach into the workspace during operation; When adjusting fixture/cleaning, it is necessary to stop the machine and cut off the air supply and power supply.

It is forbidden to short-circuit protection signals such as safety door and limit; Pause first if it is abnormal, and don't stop urgently if it is not urgent.

daily maintenance

Each shift: clean the sucker/gripper and check for wear and looseness; Clean up the sundries of guide rail and towing chain.

Weekly: Tighten bolts and lubricate guide rails; Check negative pressure and gripper pressure.

Monthly: check the temperature rise and abnormal sound of servo motor and driver; Calibration of repetitive positioning accuracy (within ±0.1mm).

Five, the unique points of plastic pallet picking

Anti-deformation: large-size trays are prone to warping, and large-area suction cups and multi-point supports are used. After taking the pieces, they are placed on a flat table to avoid stacking and squeezing.

Anti-cold marks: Avoid touching the metal fixture for a long time when taking parts from the high-temperature tray (80-120℃) to prevent the cold marks on the surface from turning white.

Beat balance: the pallet forming cycle is long, and the picking time of the manipulator is controlled within 3-5 seconds to avoid affecting the overall productivity.