How to install and debug the assembly line of electric cabinet?

Preparation before installation

Site preparation

Space requirements: the assembly line installation site should be spacious enough to accommodate the assembly equipment and operators of the electric cabinet. The site area should be determined according to the size of the assembly line and the size of the electric cabinet, and the space for material stacking, finished product storage and transportation channels should be considered. Generally speaking, at least 1.5-2 meters of channel width should be reserved around the assembly line of electric cabinets.

Ground conditions: The ground of the site should be flat and solid, and can bear the weight of the electrical cabinet assembly equipment and the electrical cabinet itself. Generally, the bearing capacity of the ground should not be less than 5kn/m. If there is heavy equipment, it may need higher bearing capacity. For uneven ground, it can be repaired by pouring concrete or laying steel plates.

Environmental requirements: the temperature and humidity of the assembly environment should be relatively stable. The ideal temperature range is 18-25℃ and the relative humidity is 40%-60%. Too high or too low temperature, too high or too low humidity may affect the quality of electrical cabinet assembly and the service life of equipment. In addition, the assembly site should be kept clean to reduce dust and impurities to prevent them from entering the inside of the electrical cabinet.

Preparation of tools and materials

Tools: prepare common mechanical tools, such as wrenches, screwdrivers, pliers, electric drills, etc., for the installation and fastening of equipment. At the same time, it is necessary to prepare electrical tools, such as multimeter, megger, wire clamp, etc., for the connection and testing of electrical circuits. The specifications of tools should be selected according to the specific equipment and line requirements of the electric cabinet assembly line.

Materials: including electric cabinet, various electrical components (such as circuit breakers, contactors, relays, fuses, etc.), wires and cables, trunking, guide rails, terminals, signs, etc. Materials should meet the design requirements and relevant standards, electrical components should have quality certificates, and the specifications and models of wires and cables should match the capacity and working environment of the electrical cabinet.

equipment inspection

Before installation, the equipment of the assembly line of the electric cabinet should be inspected. Check whether the appearance of the equipment is damaged, such as whether the cabinet is deformed or scratched, and whether the electrical components are damaged. At the same time, check whether the model, specification and quantity of the equipment are consistent with the design requirements. For key equipment, such as automatic assembly robots and CNC machining equipment, it is also necessary to check whether their performance parameters meet the requirements.

Installation process

Foundation installation

Positioning and fixing of the cabinet: place the cabinet of the electric cabinet in the predetermined position of the installation site according to the design layout. Use level and theodolite to check the levelness and verticality of the cabinet. Generally, the levelness error should not exceed 0.5 mm/m and the verticality error should not exceed 0.5 mm/m.. By adjusting the anchor bolts or adding gaskets at the bottom of the cabinet, the cabinet is firmly fixed on the ground.

Installation of equipment supporting structure: For some large or heavy electrical cabinet assembly equipment, it may be necessary to install supporting structures, such as channel steel and I-beam. During installation, the strength and stability of the supporting structure should be ensured, and the connection parts should be connected by welding or high-strength bolts, and should comply with the relevant structural design specifications.

Mechanical installation

Installation of conveying system: If the assembly line contains conveying system, such as conveyor belt, roller, chain, etc., it should be installed according to the equipment instructions. When installing the conveyor belt, pay attention to the tension adjustment of the conveyor belt. Usually, press the conveyor belt with your fingers, and the sinking amount should be 10-15 mm. At the same time, it is necessary to ensure that the driving motor, reducer and other equipment of the conveying system are firmly installed and can operate normally.

Installation of operation platform and fixture: install the operation platform to facilitate the operator to assemble the electric cabinet. The height of the platform should be suitable for ergonomics, generally 700-900mm from the ground. Install fixtures to fix the cabinet body and electrical components of the electrical cabinet to ensure the positioning accuracy in the assembly process. The installation position of fixture should be accurate and can be adjusted flexibly.

Electrical installation

Wiring planning: according to the electrical schematic diagram and wiring diagram of the electrical cabinet, plan the laying path of wires and cables. Wiring should be neat and beautiful, and try to avoid crossing and confusion. High-voltage and low-voltage lines should be laid separately with a certain spacing, and it is generally recommended that the spacing should be not less than 300mm to reduce electromagnetic interference.

Wiring: Connect the electrical wiring according to the wiring diagram. In the process of connection, ensure that the wiring is firm and avoid virtual connection or looseness. For multi-strand flexible wires, terminals should be used for connection, and tinning treatment should be carried out to prevent the ends of wires from spreading. After the connection is completed, the crimping parts shall be fastened with tools such as wire crimping pliers.

Installation of electrical components: install various electrical components in the corresponding positions of the electrical cabinet. When installing, pay attention to the installation direction and spacing of components to ensure that there is enough heat dissipation space between components. For example, the installation spacing of circuit breakers should generally not be less than 1.5 times its width. At the same time, it should be fixed according to the installation instructions of the components to ensure that the components are installed firmly.

debug phase

No-load debugging

Mechanical debugging: firstly, the mechanical part of the assembly line is debugged without load. Start the conveying system, operating platform lifting mechanism and other mechanical equipment, and check whether it runs smoothly and whether there is abnormal vibration and noise. Check whether the movement speed of the equipment meets the design requirements, and control the speed by adjusting the frequency converter or reducer. For example, the running speed error of conveyor belt should be controlled within 5%.

Debugging of electrical parts: conduct no-load debugging of electrical parts to check whether the actions of electrical components are normal. By operating the control button or PLC program, contactors, relays and other elements can act in a predetermined logical order. Use a multimeter to check the on-off condition of the circuit to ensure that the circuit is connected correctly. At the same time, check whether the grounding of electrical equipment is good, and the grounding resistance should generally not be greater than 4Ω.

Load debugging

Simulated load debugging: After no-load debugging is normal, carry out simulated load debugging. Simulated load devices, such as resistance boxes and reactors, can be used to simulate the load of the electric cabinet in actual work. Gradually increase the simulated load, observe the operation of the equipment and electrical system of the electric cabinet assembly line, and check whether the equipment can withstand the rated load and whether the electrical parameters (such as voltage, current, power, etc.) are within the normal range.

Actual load debugging: debug the actual load after the simulated load is qualified. Put the actual cabinet products or samples on the assembly line and operate according to the actual assembly process. Check the quality of electrical cabinet assembly, such as the installation accuracy of electrical components and the quality of line connection. At the same time, we should observe the operation efficiency and stability of assembly line equipment under actual load, and adjust and solve the problems in time.

Safety device debugging

Debugging of emergency stop device: check whether emergency stop devices such as emergency stop button, safety light curtain and protective door switch can work normally. After pressing the emergency stop button, all the equipment in the assembly line should stop running immediately, and after troubleshooting, it needs manual reset to restart.

Debugging of safety protection devices: debug safety protection devices such as protective fence, protective net and leakage protection device. Check whether the installation of protective devices is firm and whether the protection scope meets the requirements. The action current and action time of leakage protection device should meet the standard, and the general action current should not be greater than 30mA and the action time should not be greater than 0.1s.