What are the main points of daily maintenance and maintenance of large injection molding manipulator?

The daily maintenance of large injection molding manipulator is very important to ensure its performance, prolong its service life and ensure production safety. The following are some maintenance and maintenance points:

A, mechanical parts maintenance

Cleaning work

Regular cleaning: clean the mechanical arm, joints, fixtures and other parts of the manipulator every day or after each shift. Use a clean soft cloth, brush or compressed air gun to remove impurities such as dust, plastic chips and oil stains on the surface. For example, in the process of injection molding, plastic particles or flash of injection molded products may be attached to the mechanical hand, and if not cleaned in time, it may enter the gap of mechanical parts, affecting its motion accuracy.

Cleaning of key parts: for some parts that are easy to accumulate dirt, such as the rotating shaft of the joint and the inside of the clamping jaw of the fixture, key cleaning should be carried out. When cleaning the rotating shaft, you can use special cleaning agent and rag to wipe it carefully to ensure that the rotating shaft can rotate flexibly. For the inside of the clamping jaw, attention should be paid to cleaning up the residual plastic materials to prevent the clamping jaw from closing loosely.

Lubrication maintenance

Determine the lubrication point and lubricant: according to the manual of the manipulator, determine the parts that need lubrication, such as joint bearings, linear guide rails, screw rods, etc. Choose a suitable lubricant. Generally, high-performance synthetic grease can be used for joints moving at high speed. For linear guide rails, it may be necessary to use low viscosity lubricating oil. For example, joint bearings can be lubricated every 100-200 hours, and the grease used should have good wear resistance and oxidation resistance.

Lubrication operation specification: when lubricating, make sure that the lubricant is evenly applied or injected into the lubrication part. For some hard-to-reach parts, special lubricating tools can be used, such as oil gun and grease injector. Avoid too much or too little lubricant. Too much lubricant may lead to leakage and pollute the working environment. Too little lubricant cannot achieve good lubrication effect. At the same time, after lubrication, the manipulator should be operated for a period of time to make the lubricant fully distributed.

Mechanical parts inspection

Appearance inspection: regularly check the appearance of mechanical arms, fixtures and other components for damage. Check for deformation, cracks, wear or paint loss. For example, if the arm of a mechanical arm is obviously bent, it may affect its motion accuracy and bearing capacity; If the clamping jaw of the fixture is seriously worn, it may lead to unstable clamping of the product.

Inspection of connecting parts: check whether the connecting bolts and nuts between various parts are loose. Use a torque wrench to regularly check and tighten the bolts in key parts, such as the joint connecting bolts of the mechanical arm and the fixing bolts of the base. Loose bolts may lead to component displacement and affect the normal operation of the manipulator. At the same time, check whether there are cracks in the welding parts, especially for some heavy mechanical hands, whose structural parts may be connected by welding, and the welding quality directly affects the safety of the equipment.

Inspection of moving parts: check whether the joint movement of the mechanical arm is flexible, and whether there is any jamming or abnormal noise. You can rotate the joint manually and feel whether its resistance is normal. For linear moving parts, such as guide rails and screw rods, check the straightness and smoothness of their movement. For example, if the guide rail is worn, it may lead to jitter or deviation of the mechanical arm during the movement, which needs to be repaired or replaced in time.

Second, the electrical system maintenance

Electrical equipment cleaning

Cleaning of control cabinet: clean the control cabinet of manipulator regularly, and use dry compressed air or soft brush to remove dust and sundries in the control cabinet. Excessive dust accumulation may lead to poor heat dissipation, short circuit or signal interference of electrical components. At the same time, clean the vents and cooling fans of the control cabinet to ensure good ventilation and heat dissipation conditions.

Cleaning of electrical components: electrical components such as motors, sensors and drivers should also be cleaned. Avoid wiping with a wet cloth to prevent moisture from entering the inside of the component. Clean dry cloth can be used to gently wipe the surface of components. For some components with protective casings, the casings can be opened for cleaning, but care should be taken to avoid damaging the circuits and connecting wires inside the components.

Electrical connection inspection

Cable inspection: check the connection of electrical cables regularly to see if there is looseness, damage or aging. Especially in the parts where the manipulator moves frequently, the cable is easy to be pulled and worn. For loose connection points, tighten them in time; For damaged cables, use insulating tape or replace cables to repair them. At the same time, check whether the cable identification is clear, which is convenient for troubleshooting.

Connector inspection: check whether all kinds of electrical connectors (such as plugs, sockets, terminals, etc.) are in good contact. You can use a professional contact resistance tester to check the contact resistance of the connector, which is generally required to be in the milliohm level. For connectors with poor contact, clean, re-plug or replace them to ensure the normal transmission of signals and power.

Electrical parameter inspection and backup

Parameter inspection: regularly check the electrical parameters of the manipulator, such as the current and speed of the motor and the control parameters of the driver. Check whether these parameters are within the normal range through the monitoring software or instrument of the control system. For example, if the current of the motor rises abnormally, it may be caused by motor overload, mechanical parts stuck or electrical failure, and it needs to be checked in time.

Parameter backup: backup the important electrical parameters of the manipulator, such as PLC program and driver parameters. These backup parameters can be used to quickly restore the normal operation of the equipment when the equipment fails or the system needs to be upgraded. Backups can be stored in external storage devices or in the cloud, and the backup contents should be updated regularly.

Third, the security system maintenance

Safety device inspection

Safety light curtain inspection: regularly check whether the function of the safety light curtain is normal. Clean the surface of the safety light curtain and check whether the light emitting unit and receiving unit of the light curtain are damaged. It can be tested whether its response is sensitive by shielding the light curtain, so as to ensure that the movement of the manipulator can be stopped in time when people or objects enter the dangerous area.

Emergency stop button inspection: check whether the appearance of the emergency stop button is damaged and whether the button can be pressed and bounced normally. Regularly test the emergency stop function to ensure that the manipulator can stop all movements immediately after pressing the button and resume normal operation after troubleshooting.

Inspection of protective fence: check whether the protective fence is firm, damaged or deformed. The height and clearance of the fence should meet the safety standards to prevent people from entering the dangerous area through the clearance of the fence. At the same time, check whether the door lock of the fence works normally, and ensure that only authorized personnel can enter the working area of the manipulator.

Security program check and update

Safety program check: check whether the safety control program of the manipulator runs normally. Check whether the logical relationship in the safety program is correct, such as whether the association between the trigger of the protective device and the stop of the manipulator is accurate. The effectiveness of safety procedures can be tested by simulating safety accident scenarios.

Safety program update: With the continuous improvement of safety standards and upgrading of equipment, the safety program of manipulator should be updated in time. Pay attention to the changes of relevant safety regulations and standards, modify and improve the safety procedures accordingly, and ensure that the operation of the manipulator always meets the latest safety requirements.