What matters should be paid attention to when installing five-axis manipulator for injection molding automation manipulator manufacturers?

Matters needing attention in installation of five-axis manipulator by injection molding automation manipulator manufacturers

Five-axis injection molding manipulator has a large number of motion axes, including horizontal, pulling, up and down, rotation, lateral posture and other compound actions. Compared with three-axis manipulator, the motion posture is more complicated, and the installation process involves equipment alignment, power wiring, air source arrangement, safety protection, mold interference debugging and other links. The installation quality directly determines the subsequent operation stability and equipment safety. Factory site installation should be strictly controlled from the dimensions of preliminary survey, mechanical assembly, electrical and gas circuit, safety configuration, interference verification, debugging and acceptance.

Pre-installation site survey and foundation confirmation are the first steps. Before entering the site, it is necessary to check the model of injection molding machine, locking tonnage, template size, maximum mold opening stroke and modulus of tolerance, and confirm the installation space at the top of the machine. The transverse track, drawing stroke and lateral rotation of the five-axis manipulator need more lateral space, and it is necessary to check whether the mold, hot runner and core-pulling mechanism in the mold will conflict with the manipulator's motion trajectory. At the same time, confirm the rigidity of the injection molding machine body, whether the foot of the machine is leveled, and whether the machine is deformed or shaken. If the machine is unstable, the manipulator will resonate when moving at high speed, causing jitter and positioning deviation. It is also necessary to check the specifications of field power supply, confirm that the voltage is stable and the grounding protection is in good condition, whether the parameters, pressure, flow and cleanliness of compressed air source meet the requirements of the manipulator, reserve maintenance space on site, and do not pile materials around to block the movement range of the manipulator.

In the stage of mechanical assembly, track fixing and horizontal calibration are very important. Most of the five-axis manipulators are installed above the fixed template of the injection molding machine. First, the transverse main beam is fixed on the top plate of the injection molding machine head, and the fastening bolts must use high-strength bolts, which are locked diagonally step by step to prevent the track from being deformed due to unilateral stress. After installation, use a level meter to detect the levelness of the transverse track. The inclination of the track will lead to the increase of transverse running resistance and positioning deviation, and the long-term use will aggravate the wear of the guide rail and rack. When assembling the pulling beam and the upper and lower arms, check the pre-tightening force of the drive rack and synchronous belt, and the tightness should be controlled within the manufacturer's specification. If it is too tight, the belt will break easily, and if it is too loose, it will lose step. When installing the fixture and lateral posture rotating mechanism, check that the flange connection end face is flat, and the check washer of the fastener must be complete to prevent the screw from loosening due to high-speed reciprocating vibration. When installing end actuators such as suction cups and grippers, it is necessary to adjust the installation angle according to the product shape, and reserve enough space for demoulding and taking parts to avoid hitting the mold when taking parts.

Electrical wiring and gas pipeline installation need to be standardized. In the electrical part, the power cable, encoder signal wire and safety loop cable are routed separately, and the strong and weak current are isolated, so as to avoid the servo signal from being interfered by the frequency converter and the injection molding electromechanical cabinet, resulting in signal drift and alarm shutdown. All wiring terminals shall be tightly pressed, the wire number shall be clearly marked, and a reasonable movable margin shall be reserved for the cable. The cable shall not be pulled when the manipulator reciprocates, and the cable shall be protected by a towing chain, and the bending radius of the towing chain shall meet the standard to prevent the cable from being bent and broken for a long time. The grounding line is laid separately, and the manipulator body, control cabinet and injection molding machine share reliable protective grounding to prevent electrostatic interference and leakage risk. In terms of gas path, the triple gas source is installed near the manipulator, and the oil mist filter and decompression device regularly discharges pollutants. The gas pipe is an aging-resistant high-pressure gas pipe, and the pipeline runs neatly, and the joint is firm and airtight. The lateral posture and gripping action of the five-axis manipulator depend on pneumatic drive, and air leakage will cause unstable and falling parts, and the pipeline shall not rub against the moving parts to avoid cutting the trachea.

The installation of safety protection system and the verification of safety loop are the most important. Five-axis manipulator has many action dimensions, and its rotation and lateral posture are prone to extrusion risk, so it is necessary to install safety fence, safety grating and safety door interlocking device. The safety loop is hardwired, and it cannot rely solely on software logic. The interlocking signal between the injection molding machine and the manipulator must be docked. When the injection molding machine has not finished locking the mold and has not given the signal to allow the parts to be taken, the manipulator is prohibited from entering the mold area. During the action of the manipulator in the mold, the injection molding machine cannot close the mold. The emergency stop button needs to be arranged at multiple points. The control cabinet and the machine-side operation box are equipped with emergency stop, and the emergency stop loop is verified in series. When the emergency stop is pressed, all motion axes will stop immediately and the power output will be cut off. After installation, test the scene of safety grating shielding and safety door opening, and verify whether the manipulator stops immediately to prevent mold crushing and equipment collision accidents.

Interference check and ontology debugging cannot be omitted. After the mechanical installation is completed, the inching low-speed trial run shall be carried out first, and it is forbidden to run directly and automatically. Manually move the manipulator axis by axis, simulate the complete picking process, check the whole path of horizontal, up and down, drawing and lateral rotation in turn, check the interference points of the manipulator arm, fixture and mold, template, hot nozzle, ejector pin and oil cylinder, and focus on checking whether the parting surface of the mold is scraped during lateral rotation. Double protection of soft limit and hard limit is set, soft limit is set in the program, and hard limit mechanical stop is used as the bottom protection to prevent over-travel impact. Adjust the pressure of the end clamp and sucker. If the pressure is too high, the product will be crushed, and if the pressure is not enough, the parts will fall off. Adjust the adsorption and clamping parameters according to the thickness of the product. At the same time, debug the handshake sequence between the manipulator and the injection molding machine, eject the signal, allow the door to open, and take the parts to complete the signal sequence matching, so as to avoid the disorder of the action sequence.

Final machine acceptance and pre-delivery inspection. After the low-speed cycle of the whole machine is normal, gradually increase the running speed, and continuously test run with no load, observe the running noise and vibration, check the temperature of guide rail and bearing, and check the abnormal sound. Carry out trial production of belt products after no-load error, verify the stability of taking parts and the positioning accuracy of products, and confirm the defects such as falling parts and clamping injuries. Re-inspect all fasteners for the second time to confirm that they are not loose, arrange electrical drawings and operation manuals, train on-site operators on safety and basic operation, inform daily routine inspection items, such as air source drainage, rail lubrication, cable inspection, etc., and leave fault alarm instructions. After the installation is completed, make installation records, and keep the data of level detection, safety loop test and interference inspection for later maintenance.