The precision inspection of non-standard automated equipment should be carried out from three dimensions: mechanical, electrical, and motion control. Professional tools and standardized procedures should be combined to ensure that the equipment performance meets the standards. The specific methods are as follows:

I. Inspection of Mechanical structure accuracy

Straightness and parallelism detection

Tools: Laser interferometer (for high-precision scenarios), straightness meter (for cost-sensitive scenarios).

Method

Laser interferometer: It measures the deviation of the guide rail movement trajectory through the reflection of the laser beam and is suitable for high-precision requirements (such as ±0.005mm).

Straightness meter: It moves along the guide rail to measure the deviation from the reference line. The operation is simple but the accuracy is relatively low (±0.02mm).

Parallelism detection: Use a dual-frequency laser interferometer or laser collimator to measure the relative position changes between two guide rails to ensure the accuracy of multi-axis linkage.

Dimensional and assembly inspection

Tools: calipers, micrometers, three-coordinate measuring machines.

Method

Routine dimension inspection: Verify the tolerance range of the processed part against the drawing (such as ±0.05mm).

Assembly inspection: Verify whether the connections of each component are firm, without any loosening or interference.

Case: The welded parts need to be inspected for defects such as undercutting, porosity and cracks to ensure structural strength.

Ii. Inspection of Electrical System Accuracy

Control circuit inspection

Tools: Multimeter, oscilloscope.

Method

Disconnect the main circuit, connect the control circuit and conduct a no-load test to check the reliability of the component operation sequence, interlock links and protection devices (such as emergency stop buttons).

Verify whether the trigger positions of the travel switch and limit switch are accurate, and there is no jamming or overheating of the contacts during contact.

Standard: The components operate flexibly, without noise, and the coil temperature is ≤65℃.

Insulation performance testing

Tool: Megohmmeter.

Method

After cleaning the dust on the conductive parts, measure the insulation resistance between the metal casing of the electrical appliance, the main circuit and the control circuit (≥0.5MΩ).

Check whether the grounding system is standardized, and whether the grounding wire is firm and has good contact.

Iii. Inspection of Motion Control Accuracy

Positioning accuracy detection

Tools: Laser interferometer, dial indicator.

Method

Laser interferometer method: A reflector is set on the guide rail, and the deviation between the actual displacement and the commanded displacement (such as ±0.01mm/m) is measured by a laser beam.

Dial indicator method: Fix the dial indicator at the end of the guide rail, drive the equipment to position it multiple times to the same position, and record the fluctuation range of the readings.

The positioning accuracy must meet the design requirements of the equipment (such as ±0.02mm/300mm).

Repeat positioning accuracy detection

Tools: Electronic dial indicator, grating ruler.

Method

Select three positions at the midpoint and both ends of the guide rail travel. Repeat the positioning at each position seven times. Calculate half of the maximum difference as the repeat positioning accuracy (such as ±0.005mm).

Grating ruler method: The deviation distribution of multiple positioning is statistically analyzed through the feedback signal of the grating.

Case: The repeat positioning accuracy of the X-axis driven by a servo motor should be ≤0.01mm.

Reverse error detection

Tools: Laser interferometer, Angle encoder.

Method

Measure the positional deviation of the guide rail when it moves in the forward and reverse directions, comprehensively reflecting errors such as the reverse clearance and elastic deformation of the transmission chain (e.g., ≤0.02mm).

The indexing error of the rotary table needs to be detected. Use a standard rotary table or a circular grating to compare the actual rotation Angle with the theoretical value.

Iv. Comprehensive Performance Verification

Load testing

Method: Clamp the workpieces for simulated working tests (10 to 1000 pieces), calculate the pass rate and monitor the fluctuations of parameters such as current, air pressure and oil pressure.

Standard: Continuous operation for 8 hours without failure, and the wear frequency of vulnerable parts meets expectations.

Safety function verification

Method

When there is a sudden power outage, check whether all motion modules stop immediately.

When personnel enter dangerous areas, verify the response time of safety light curtains or emergency stop devices (≤0.2 seconds).