Jiangsu Tianqixing Robot: The Solution of Five-axis Injection Manipulator in the Injection Molding of Auto Parts

The injection molding production of automobile parts has strict standards on dimensional consistency, appearance quality, process traceability and production stability. The plastic parts such as interior trim, structural support, lamp housing and wiring harness connector generally have technical difficulties such as inverted structure, easy deformation of thin wall and embedded parts in the mold. The traditional three-axis manipulator has limited freedom of movement, and it is difficult to meet the production needs of multi-angle picking, attitude adjustment and complex process integration. Jiangsu Tianqixing Robot is based on the Yangtze River Delta intelligent manufacturing industrial belt, and relies on years of research and development of injection automation to launch a special solution for injection molding of automobile parts with five-axis full servo injection manipulator, so as to create an automatic production unit with high precision, high flexibility and traceability for automobile parts injection enterprises, help enterprises adapt to the PPAP quality control system of the main engine plant, and achieve the goals of improving quality, reducing costs and increasing efficiency.

The five-axis injection molding manipulator of Tianqixing adopts five-axis AC servo cooperative drive architecture, and the multi-degree-of-freedom movement can complete multi-angle rotation, lateral picking, posture flipping and other actions, effectively solving the pain points such as demoulding interference and backward picking of complex automobile plastic parts. It is suitable for injection molding machines with specifications ranging from 50 tons to 1,600 tons, covering the production scenes of small and medium-sized precision connectors, interior door panels, bumper brackets, car lampshades and other all kinds of automobile injection molding parts. The equipment is equipped with closed-loop servo drive system and self-optimized S-type acceleration and deceleration motion algorithm, with stable and controllable repetitive positioning accuracy, smooth start and stop of the arm, no impact and low running jitter, which avoids scratching the appearance of the A-side of the product during the picking process and greatly reduces the high incidence of customer complaints such as scratches, indentations and deformation of the interior decoration. In view of the diversified material characteristics of automobile plastic parts, Tianqixing can customize the chemical fixture, and the appearance parts are made of non-precipitated and non-trace silicone suction cups, avoiding the visible area to arrange adsorption points; The structural parts are matched with adjustable soft rubber clamping jaws to accurately control the clamping force, taking into account the stability of taking parts and product protection; Aiming at the embedding process of inserts such as nuts and copper sleeves, the tolerance of tooling positioning pins is strictly controlled to ensure the accurate placement of inserts and eliminate the risk of die pressing and offset scrapping.

The whole scheme supports multi-process integration, and can realize continuous operations such as in-mold embedded inserts, product shaping and lifting, automatic plate setting, conveying and docking, on-line dust removal and blowing, etc. besides basic parts picking and nozzle shearing. The manipulator control system reserves a standardized communication interface, which can seamlessly connect with MES production management system, automatically record the production beat, servo operation parameters and equipment alarm information of each module, form a complete production data chain, and meet the requirements of product traceability in the automobile industry. The equipment has built-in perfect safety interlock logic of injection molding machine, which is linked with low-voltage protection of mold, safety door signal and ejection in place signal. It is equipped with safety grating, area protection and multiple limit protection, which can stop and lock immediately in case of abnormality to prevent mold collision and misoperation, protect high-value automobile mold and prolong its service life. At the same time, multiple sets of mold formulas are built into the system, and the motion coordinates and process parameters can be retrieved with one click when changing molds, which greatly shortens the time for changing and debugging multi-variety and small-batch orders in the auto parts industry and reduces the quality fluctuation caused by manual debugging.

Combined with the working conditions of the auto parts workshop, Tianqixing has made special optimization on the structure and protection level, strengthened the rigidity of the fuselage, and designed the guide rail, screw rod and servo motor to prevent dust, oil and gas, resist the corrosion of oil and gas from the release agent and plastic dust, and adapt to the long-term continuous 24-hour production in the injection workshop. All models have been tested at full load for 72 hours before leaving the factory, which keeps stable operation during long-term cycle production and reduces the downtime failure rate. At the same time, supporting a one-stop service system, arranging process engineers to survey the layout of the workshop on the spot before the sale, evaluating the difficulties in product molding, and issuing exclusive layout plans; Complete installation and debugging, first article verification, operator training on site, standardize parameter modification authority, and avoid quality hidden trouble caused by arbitrarily changing servo gain and motion curve; Establish a quick response channel after sale, pay regular visits to spot checks, and provide continuous services such as maintenance guidance, troubleshooting, and iterative upgrading of fixtures.

At present, the automobile industry is developing in the direction of light weight and intelligence, and auto parts injection molding enterprises are facing multiple pressures such as continuous improvement of quality threshold, rising labor costs and compressed delivery cycle. Jiangsu Tianqixing five-axis injection manipulator injection solution for automobile parts breaks the limitation of single picking of traditional automation equipment by combining flexible automation equipment with process service ability, and helps automobile parts injection enterprises to build standardized and digital injection production units, stabilize the yield, reduce field workers and improve the productivity of production lines. In the future, Tianqixing robot will continue to deepen the injection molding automation track, continuously iterate the servo control algorithm and integration scheme, provide reliable domestic automation equipment for more auto parts manufacturers, and work together to promote the intelligent manufacturing upgrade of auto parts injection molding industry.