What are the specific steps for debugging and installing the motor automatic assembly line?

Pre-installation preparation stage

Site preparation

Choose a suitable site to ensure that the site area meets the layout requirements of the assembly line, and the ground is flat and solid, which can bear the weight of the assembly line equipment. For example, for a large-scale motor automatic assembly line, a special industrial workshop floor may be needed, and its carrying capacity generally reaches several tons per square meter.

According to the size and operation requirements of assembly line equipment, plan the equipment installation location and personnel passage. The channel width is usually not less than 1-1.5 meters, which is convenient for equipment maintenance and operators to walk around. At the same time, it is necessary to ensure that the site environment meets the requirements of the equipment, such as the temperature is controlled within the range specified by the equipment (generally at 18-25℃), the humidity is kept at an appropriate level (40%-60%), and the site is kept clean to reduce the influence of impurities such as dust on the equipment and motor parts.

Equipment inspection and handling

After receiving the equipment, carefully check whether the quantity of all equipment and spare parts is complete according to the equipment list. Check whether the appearance of the equipment is damaged, deformed, bumped, etc., and focus on the key equipment of motor automatic assembly, such as the mechanical arm of the robot, the conveyor belt and roller of the conveyor.

When transporting the equipment to the installation site, use appropriate handling tools, such as forklifts and cranes, and operate according to the center of gravity position and lifting requirements of the equipment to avoid secondary damage to the equipment during handling. For precision equipment, appropriate protective measures should be taken, such as using shock absorbing pads and protective sleeves.

Preparation of tools and materials

Prepare to install all kinds of tools needed, such as hand tools such as wrenches, screwdrivers, pliers, Allen wrenches, and electric tools such as electric screwdrivers and pneumatic wrenches. At the same time, according to the requirements of equipment installation, prepare measuring tools, such as calipers, micrometers, level meters, theodolite, etc.

Prepare materials needed for assembly line, such as bolts, nuts, washers, seals, lubricating oil, grease, etc. Ensure that the quality of materials meets the requirements of motor assembly, for example, the strength grade of bolts should match the requirements of equipment connection, and the type of lubricating oil should be suitable for the lubrication of motor components.

Equipment installation stage

Foundation installation

For large equipment, such as automatic assembly machine and heavy conveyor, it is necessary to install concrete foundation. Design the size and reinforcement of the foundation according to the size, weight and vibration characteristics of the equipment. In the process of foundation construction, anchor bolt holes should be accurately reserved to ensure that the position and depth of anchor bolts meet the requirements of equipment installation.

Place the equipment on the foundation and preliminarily fix it by anchor bolts. Use a spirit level to level the equipment, and adjust the nuts on the anchor bolts to make the equipment reach the specified levelness. The levelness error of general equipment should be within ±0.1mm/m/m. For small equipment, it can be installed on a steel bracket, and it is also necessary to ensure that the bracket is firmly installed and the equipment is level.

Installation of mechanical parts

According to the design layout of the assembly line, mechanical components such as conveyor, assembly workbench and robot base are installed. When installing the conveyor, ensure that the tension of the conveyor belt is moderate and the axes of the rollers are parallel to avoid the deviation of the conveyor belt. When installing the assembly workbench, ensure that the flatness of the workbench and the height difference with other equipment meet the assembly requirements.

Install and assemble the robot and its auxiliary mechanical parts, such as mechanical arms and end effectors (such as jaws and tightening tools). In the installation process, we should operate according to the installation instructions of the robot manufacturer, accurately adjust the joint angle and position of the manipulator, and ensure that the motion range and accuracy of the manipulator meet the requirements of the motor assembly task.

Electrical system installation

Lay cables and wires according to the electrical schematic diagram and wiring diagram. Select wires and cables with appropriate specifications, and determine the cross-sectional area and insulation grade of wires according to the parameters such as power, current and voltage of equipment. For example, for high-power motor-driven equipment, cables with large cross-sectional area should be used to prevent the wires from overheating.

Connect electrical equipment such as motors, sensors and controllers. In the process of connection, pay attention to the color mark of the wire and the number of the terminal to ensure correct wiring. At the same time, it is necessary to carry out grounding protection, and connect the metal shell of the equipment and the grounding terminal of the electrical control cabinet with the grounding system of the workshop reliably, and the grounding resistance is generally required to be no more than 4Ω.

Installation of piping system (if there is a hydraulic or pneumatic system)

For assembly lines with hydraulic or pneumatic systems, install hydraulic pipes and pneumatic pipes. The material, diameter and wall thickness of the pipeline should be selected according to the pressure, flow rate and working medium of the system. Before installation, the pipeline should be cleaned and purged to remove impurities and oil stains in the pipeline.

Connect hydraulic and pneumatic equipment such as hydraulic pump, cylinder and valve to ensure tight connection and no leakage. After the installation of pipeline system is completed, pressure test shall be conducted. Generally, the test pressure of hydraulic system is 1.25-1.5 times of working pressure, and that of pneumatic system is 1.1-1.2 times of working pressure. The test time shall not be less than 10-15 minutes, so as to check whether the pipeline system is leaking.

debug phase

No-load debugging

After completing the equipment installation, first carry out no-load debugging. Turn on the power supply, start all the equipment of the motor automatic assembly line, including conveyor, assembly robot, tightening equipment, etc., and observe whether the equipment can be started normally. Check whether the running direction of the equipment is correct, for example, whether the conveyor belt of the conveyor runs in the set direction.

Check whether the running speed of the equipment meets the design requirements. Adjust the running speed of the equipment by operating the speed control button on the control cabinet or adjusting the parameters of the frequency converter. Observe whether the equipment has abnormal vibration, noise or overheating during no-load operation. For the assembly robot, it is necessary to check whether the movement of the mechanical arm is smooth and smooth, and whether there is any jamming or abnormal sound at the joints.

Test the signal transmission and interlocking function between devices. For example, when the sensor on the conveyor detects the material position signal, can it be correctly transmitted to the assembly robot to make the robot start the grabbing action? Check whether the emergency stop function of the equipment is normal, and whether all equipment can stop running immediately after pressing the emergency stop button.

Load debugging

After no-load debugging is normal, carry out load debugging. Put the motor parts on the assembly line to simulate the actual motor assembly process. At the beginning, run at a lower load and a slower speed, and observe the running state of the equipment under load. Check whether the equipment can stably complete the motor assembly task, such as whether the robot can accurately grab the parts and assemble them, and whether the tightening equipment can complete the bolt tightening operation within the specified torque range.

Monitor the performance parameters of the equipment, such as current, voltage, power and torque of the motor. These parameters are obtained by sensors or instruments installed on the equipment and compared with the rated parameters of the equipment. If abnormal parameters are found, such as excessive motor current or insufficient torque, the reasons should be analyzed in time, which may be excessive equipment load, excessive friction of mechanical parts or electrical system failure, and the equipment needs to be adjusted and optimized.

Check the quality of the assembled motor. Conduct a preliminary inspection of the assembled motor, including whether the appearance of the motor is damaged and whether the parts are assembled in place. Use professional testing equipment, such as insulation resistance tester and winding short circuit tester, to check whether the electrical performance of the motor meets the requirements. At the same time, check the mechanical properties of the motor, such as axial clearance and radial runout, to ensure that the assembly quality of the motor reaches the standard.