120T Injection Molding Machine: Installation and Debugging Guide for Three-Axis Robot

Table of Contents

1. Pre-Installation Preparation & Site Conditions
2. Mechanical Installation of Three-Axis Robot
3. Wiring, Pneumatic Connection & Safety Checks
4. Parameter Setting & Coordinate Calibration
5. Joint Debugging with 120T Injection Molding Machine
6. Test Run, Production Verification & Optimization
7. Daily Maintenance & Common Fault Solutions
8. Conclusion

1. Pre-Installation Preparation & Site Conditions

Basic Requirements

• Injection Molding Machine: 120T standard horizontal model, normal mold opening/closing, ejection function available
• Robot Model: Three-axis servo traverse Robot Suitable for 100–160T injection machines
• Installation Space: Sufficient clearance for robot traverse, no obstacles above the mold area
• Foundation: Stable, level ground; vibration ≤ standard industrial allowable value
• Power Supply: 3PH 380V/220V (according to robot manual), stable voltage
• Air Supply: Clean, dry compressed air, pressure 0.5–0.7 MPa

Tools & Accessories

• Socket wrench set, hex keys, torque wrench
• Level gauge, marker pen, measuring tape
• Cable ties, air hoses, connectors, safety guards
• Operation manuals of robot and injection machine

2. Mechanical Installation of Three-Axis Robot

2.1 Frame & Base Installation

1. Clean the installation area on the injection machine’s fixed platen or auxiliary base.
2. Place the main frame and use a level to adjust horizontal accuracy.
3. Lock fixing bolts with a torque wrench to specified torque.
4. Double-check stability; no looseness or tilting allowed.

2.2 Arm & Traverse Axis Assembly

1. Install the vertical arm, ensuring perpendicularity to the main beam.
2. Mount the traverse unit and set effective stroke matching the 120T machine’s mold width.
3. Install the wrist/end-effector base and confirm smooth motion without jamming.
4. Check sliding parts and guide rails; add lubricant if needed.

2.3 Safety Limit & Guard Installation

1. Install hard limit switches for each axis.
2. Mount safety baffles and anti-collision components.
3. Ensure guards do not block normal operation or maintenance access.

3. Wiring, Pneumatic Connection & Safety Checks

3.1 Electrical Wiring

1. Connect the main power cable to the robot control cabinet.
2. Run signal cables between the robot and the injection machine’s I/O terminal.
3. Connect servo motors, encoders, and sensors correctly.
4. Grounding must be reliable to reduce electromagnetic interference.

3.2 Pneumatic System

1. Connect main air line to the robot’s air manifold.
2. Install air filter regulator and set pressure to 0.5–0.6 MPa.
3. Check cylinders, solenoid valves, and joints for leaks.
4. Test gripper opening/closing for smooth action.

3.3 Pre-Start Safety Inspection

• All emergency stop buttons function normally.
• Safety doors and guards are in place.
• No loose wires or exposed terminals.
• Air pressure and voltage are within rated ranges.

4. Parameter Setting & Coordinate Calibration

4.1 Basic System Parameters

• Origin setting for X/Y/Z axes
• Stroke limits, soft limits
• Servo gain, speed, acceleration
• Gripper clamping/retracting delay

4.2 Coordinate Calibration

1. Return all axes to mechanical origin.
2. Set mold center position and safe position.
3. Calibrate take-out position and placement position.
4. Verify repeat positioning accuracy; adjust if deviation exceeds allowable range.

4.3 I/O Signal Matching

• Injection machine mold opening in-place signal
• Ejection completion signal
• Robot take-out permission signal
• Alarm interlock signals

5. Joint Debugging with 120T Injection Molding Machine

5.1 Signal Interlock Debugging

1. Verify that the robot only enters the mold area after mold opening is confirmed.
2. Ensure the injection machine cannot close the mold while the robot is inside the mold space.
3. Test emergency stop: any E-stop triggers both robot and machine to halt immediately.

5.2 Action Flow Debugging

1. Mold fully open → robot enters mold
2. Gripper clamps product → retracts to safe position
3. Robot exits mold area → injection machine closes mold
4. Robot places product → returns to waiting position

5.3 Speed & Timing Optimization

• Adjust entry/exit speed to avoid impact.
• Set reasonable delay for gripper action.
• Balance speed and stability to prevent product dropping or deformation.

6. Test Run, Production Verification & Optimization

6.1 Manual Test Run

• Operate each axis individually to check smoothness.
• Test gripper, cylinder, and safety functions.

6.2 Semi-Automatic Test Run

• Trigger one cycle manually to confirm full process completion.
• Check product quality, no scratches, deformations, or residues.

6.3 Automatic Continuous Operation

• Run 30–60 consecutive cycles to monitor consistency.
• Check for abnormal noise, vibration, or overheating.
• Optimize cycle time to improve efficiency without compromising quality.

7. Daily Maintenance & Common Fault Solutions

Daily Maintenance Items

• Clean guide rails, sensors, and grippers.
• Check air pressure and lubrication.
• Tighten bolts and inspect cables.

Common Faults & Solutions

8. Conclusion