Jiangsu Tianqixing Robot Introduction: Key Points for Attention in Installation Process of Five-axis Injection Molding Manipulator

Compared with the three-axis model, the five-axis injection manipulator has two degrees of freedom: arm rotation and wrist rotation at the end, which can realize high-end processes such as complex posture picking, in-mold embedding, multi-station turning, etc. Its installation accuracy directly determines the operation stability, positioning accuracy and service life. The whole process needs to strictly control the three cores of mechanical accuracy, interference protection and electrical matching. The specific precautions are as follows:

Before installation, it is necessary to complete the basic verification. First, check the matching of the manipulator model with the tonnage and mold opening stroke of the injection molding machine, and confirm that the size deviation of the installation hole position of the fixed template of the injection molding machine is ≤2mm, and it is forbidden to force reaming and assembly. The pedestal installation is the benchmark of the whole machine's accuracy. It must be fixed on the injection molding machine template or special steel pedestal, and it is forbidden to install directly on the sheet metal shell. The levelness deviation of the installation surface is ≤ 0.05 mm/m. The anchor bolts are tightened symmetrically step by step, and the torque is even and consistent, so as to avoid tilting deformation of the machine body. After installation, the levelness of the machine body is re-measured to ensure that the machine body does not shake when the load is running.

In the installation stage of mechanical shaft, the assembly of three linear shafts, i.e. horizontal shaft, drawing shaft and upper and lower shaft, should be completed first. The seam of guide rail should be less than or equal to ≤0.03mm, and the whole straightness deviation should be less than or equal to 0.08 mm. The slider should run without jamming and clearance, and the meshing clearance of rack and gear should be controlled at 0.1-0.15 mm. If the clearance is too large, it will lead to positioning deviation, while if it is too small, it will aggravate wear. The core control points of five axes are two rotating axes, and the coaxiality of the rotating axes of the arm needs to be calibrated with a dial indicator, and the deviation is ≤0.05mm to avoid periodic jitter during rotation; The axial and radial clearance of the wrist rotating shaft shall be ≤0.02mm, and there shall be no dead point and jamming in the whole rotation process. The output shaft of the reducer and the rotating flange must be coaxially aligned, and it is forbidden to forcibly knock and assemble, otherwise the internal gear of the reducer will be damaged and the service life will be greatly shortened.

The terminal fixture and pipeline installation need to adapt to the multi-axis motion characteristics. After fixture installation, dynamic balance calibration is needed to avoid vibration during high-speed rotation. The perpendicularity between fixture positioning surface and wrist rotation axis is ≤0.05mm, so as to ensure accurate posture. There are more five-axis motion pipelines, so it is necessary to reserve enough margin for each rotation and linear motion, and reserve 15-20cm space for each joint. The pipelines are protected by towing chain and double-layer corrugated pipe, and there is no distortion or pulling in the whole process. The power line, signal line and trachea are arranged in bundles, and the shielding layer of signal line is grounded at one end, so as to avoid electromagnetic interference during rotation, causing servo alarm, position loss and other failures.

All-attitude interference inspection is the core difficulty of five-axis installation. Five-axis motion posture is far more than three-axis, so it is necessary to manually drive each axis slowly to the maximum stroke and limit rotation angle, and simulate all working postures such as mold opening and taking, arm rotation, fixture turning, embedded part placement, etc., and check the gap between the manipulator and the injection molding machine template, mold, safety door and peripheral equipment in the whole process to confirm that there is no collision risk in all postures. Double protection of soft limit+mechanical hard limit and limit switches are set at both ends of the stroke.

In the final debugging stage, the servo gain and filtering parameters are adjusted one by one at low speed, and the following error of the rotating shaft is optimized to avoid resonance during medium and high speed operation. Then, the origin regression calibration is completed, and the repeated regression accuracy is ≤±0.03mm, and then the five-axis linkage test is carried out, and the positioning accuracy of the typical picking posture is ≤±0.1mm；; Finally, mount the rated load for continuous trial operation for 2 hours, check the temperature rise and vibration of the rotating shaft, and confirm that there is no abnormal noise, precision attenuation and pipeline pulling wear.

The core difference in the installation of five-axis injection molding manipulator lies in the precision control of the rotating shaft and the full attitude interference protection. Compared with the three-axis model, it pays more attention to the motion stability under multiple degrees of freedom, and strictly controls the assembly accuracy of each step to ensure the yield of subsequent production and the long-term reliability of the equipment.