What should be paid attention to in the installation and debugging of TV detection conveyor line?

The installation and debugging of TV detection conveyor line directly affects the subsequent detection efficiency, equipment safety and TV product quality. It needs to be carried out around the four cores of "structural stability, functional adaptability, safety compliance and operation and maintenance convenience". The specific precautions can be divided into four key links: preparation before installation, installation process, debugging stage, acceptance and delivery. Details are as follows:

First, preparation before installation: avoid the early risks.

On-site environmental verification

Confirm the flatness of the ground in the installation area (the error should be ≤3mm/m) to avoid the deviation of the conveying line caused by the ground inclination; The ground should have enough bearing capacity (usually ≥500kg/㎡ according to the total weight of transmission line+TV load) to prevent the ground from settling after long-term use.

Clear the obstacles (such as pipelines, columns and temporary equipment) on site, reserve an operation channel with a width of at least 1.2m (in line with safety regulations), and check that the interface positions of power supply (independent 380V three-phase five-wire loop with voltage fluctuation ≤ 5%) and air source (if pneumatic detection components are included, the air pressure should be stabilized at 0.6-0.8MPa) match the design of the conveying line.

Check equipment and drawings.

According to the design drawings (including mechanical structure diagram, electrical schematic diagram and layout diagram), the models, quantities and specifications of conveyor line components (such as frame, conveyor belt, driving motor, detection station bracket and guide mechanism) are counted one by one, and the key components (such as motor power and whether the material of conveyor belt can resist the friction of TV casing) are checked to see if they are consistent with the design.

Confirm TV parameters (size, weight, inspection station requirements). For example, if a 55-75 inch TV is to be transported, the width of the conveyor belt should be reserved with a redundancy of ≥200mm (to avoid side collision), and the height of the bracket should be adapted to the operation of the inspectors (usually the table top is 0.8-1.0m from the ground).

Second, the installation process: guarantee structure and functional basis

Installation of frame and conveying system

Rack assembly shall be based on the principle of "main frame first, then auxiliary frame, then horizontal and then vertical", and the levelness (longitudinal error ≤1mm/m, lateral error ≤0.5mm/m) of each section of rack shall be calibrated with a spirit level, and it shall be fixed on the ground by expansion bolts (bolt size ≥M12, buried depth ≥100mm to ensure vibration resistance); When multi-section racks are connected, the gap at the joint should be ≤0.5mm to prevent the conveyor belt from being stuck.

Pay attention to "tension and centering" when installing the conveyor belt: the belt conveyor line needs to adjust the tension roller to make the belt tension uniform (press the belt by hand, and the sinking amount should be ≤15mm); Chain conveyor line needs to calibrate sprocket alignment to avoid chain deviation and wear; At the same time, the surface of the conveyor belt should be clean and free of oil to prevent the TV shell from being polluted.

Installation of inspection station and auxiliary components

Detection stations (such as power-on test bench, appearance detection rack and weight detection module) need to be accurately butted with the conveying line, and the height difference between the table top of the station and the surface of the conveying belt is ≤2mm to avoid bumping when the TV is transferred; The cables and gas pipes for detection shall be fixed through the pipes (to avoid hanging), and sufficient length shall be reserved (to adapt to the running stroke of the conveying line) to prevent pulling and breaking.

The installation of guiding mechanisms (such as side gears and positioning cylinders) should be consistent with the conveying track of the TV set, the distance between the side gears and the side of the TV set should be controlled at 5-10mm (neither collision nor deviation), and the telescopic stroke of the positioning cylinder should be accurate (error ≤1mm) to ensure that the TV set is in a fixed position during detection.

Electrical system installation

Wires and cables should be wired separately from weak current (sensor, PLC) according to "strong current (motor, heating)", the threading pipe should be fixed firmly, and the joint should be waterproof and insulated (especially if there is humid environment in the workshop); The PLC control cabinet should be installed in a ventilated and vibration-free position, and the temperature in the cabinet should be controlled at 0-40℃ (to avoid overheating of components).

The installation position of sensors (such as photoelectric switch and proximity switch) should be accurate: the photoelectric switch should be aimed at the center of the conveyor belt, the detection distance should be adjusted to "only recognize the TV set (do not accidentally trigger the blank line)", and the distance between the proximity switch and the positioning component (such as the stop) should be ≤5mm to ensure stable signal transmission.

Third, the debugging stage: to achieve "accurate transportation+reliable detection"

No-load debugging: verifying basic functions

Start the conveyor line and run it for 30-60 minutes with no load. Check: ① Whether the running speed of the conveyor belt is consistent with the design (error ≤ 2%), and there is no deviation (the distance between the edge and the side of the frame is ≤3mm) and slippage; ② The driving motor and reducer are free from abnormal noise (decibel ≤70dB) and overheating (surface temperature ≤ 60℃); ③ Whether all sensor and switch signals are normally fed back to the PLC, and there is no "false alarm or omission".

Test the emergency stop function: trigger the emergency stop button along the line (at least one button every 10m) and the emergency stop switch of PLC cabinet. The conveying line needs to stop within 1 second, and the motor is powered off and the brake (if any) takes effect to prevent inertia sliding.

Load debugging: simulating actual working conditions

Step-by-step test according to "light load to full load": first, put 1-2 empty TV sets (simulating the actual product weight) to observe whether the conveying line runs smoothly and whether the TV sets are offset and collided; Then test according to the designed maximum load (for example, carrying 5 TV sets per meter of conveyor line), and check whether the motor load current is within the rated range (not more than 1.1 times the rated current), and whether the tension of conveyor belt needs to be adjusted (to avoid drooping due to load).

Linkage debugging of inspection stations: simulate the inspection process (transportation → positioning → inspection → release), and test the linkage logic between each station and the conveying line: for example, after the TV arrives at the inspection station, the conveying line needs to stop automatically, and the positioning cylinder is fixed. After the inspection is completed, the cylinder is retracted, and the conveying line continues to run. The whole process needs to be free of jamming (response time ≤0.5 seconds), and in case of failure (such as abnormal detection), it needs to stop automatically and give an alarm.

Precision debugging: ensuring detection reliability

Adapting and debugging for the detection function: if the detection station needs "power-on test", it is necessary to verify the docking accuracy of the power cord connector and the TV interface (there is no dislocation during manual or automatic docking); If "appearance inspection" is needed, the pause time of the conveyor line should be adjusted (to meet the observation and photographing requirements of the inspection personnel/equipment, usually 3-10 seconds), and the pause position error should be ≤1mm (to ensure that the inspection area is aligned with the key parts of the TV).

Error calibration: use standard parts (such as "standard TV model" with known size and weight) for testing. If transportation deviation and inaccurate positioning are found, it is necessary to fine-tune the position of guide mechanism and sensor; If the speed deviates, it is necessary to adjust the motor frequency through PLC parameters until all indicators meet the design requirements.

Iv. acceptance and delivery: define responsibilities and operation and maintenance.

Compliance acceptance

According to the design drawings and industry standards (such as GB 19517, Safety Code for Conveying Machinery), check: ① Whether the safety protection (such as the height of guardrails on both sides of the conveyor belt is ≥1.1m, the emergency stop button is clearly marked, and the electrical grounding resistance is ≤4Ω) is up to standard; ② Whether the delivery efficiency (such as the number of TV sets delivered per hour) meets the design value; ③ Whether the accuracy of the detection station (such as positioning error and signal feedback accuracy) is ≥99.9%.

Documentation and training delivery

Arrange delivery documents: including installation and debugging records (including parameters and test data of each link), equipment drawings (electronic version+paper version), operation manuals (including daily start-stop and troubleshooting steps) and maintenance manuals (including maintenance cycles and methods of motors, conveyor belts and sensors).

Train the operation and maintenance personnel: mainly explain the "normal operation process, emergency stop use scenarios, and common fault handling (such as belt deviation adjustment and sensor fault replacement)" to ensure that personnel can operate independently and maintain the foundation to avoid equipment damage due to improper operation.

Through the strict control of the above links, the "safe, efficient and accurate" operation of the TV detection conveyor line can be ensured, providing stable hardware support for the subsequent TV detection links.