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In many industrial applications, surface treatment and processing of non-standard parts are essential. Due to the complexity and variety of these surfaces, manual operations are often impractical, while general-purpose robots also face limitations due to their fixed structures. As a result, the development of custom, non-standard robotic systems has become a crucial technical field. These systems often require specialized knowledge and tailored solutions, making them an important part of modern manufacturing.
With the growing demand for personalized products, aluminum alloy electroplated car hubs have become more complex and diverse, leading to frequent replacements. Currently, most manufacturers rely on manual polishing during the wheel hub production process, which accounts for about 35% of total time and labor. This method depends heavily on skilled workers, who can polish only 1–3 hubs per day. The high dust levels generated during polishing pose serious health risks to workers and cause environmental pollution. Additionally, the low efficiency and high physical strain significantly hinder business growth.
To address these challenges, Nachi has introduced a cost-effective polishing robot system specifically designed for the automotive wheel industry. This system offers high efficiency, capable of replacing the work of 3–4 workers. It boasts reliability with 80,000 hours of continuous operation without failure. The product quality is excellent, meeting most process requirements through our torque belt machine, achieving up to 99.2% yield. The system is highly flexible, with patented offline programming software that allows for quick setup—only 30 minutes of downtime is needed to teach new workpieces, compared to 7–8 days required by other systems. It also reduces labor intensity, as each workstation only requires loading and unloading every 8 hours, with no need for constant worker intervention. The overall cost is low, with a robot system paying for itself in 2–3 years compared to hiring workers. With just one operator, it can run 24/7, boosting production and enhancing company competitiveness.
Common polishing methods include electropolishing, ultrasonic polishing, jet polishing, magnetic polishing, mechanical polishing, and chemical polishing. After extensive research and testing, our technicians have found that mechanical and chemical polishing are the most feasible for wheel hub finishing.
Chemical Mechanical Polishing (CMP) involves pressing the workpiece against a rotating or flowing polishing slurry. During the process, the slurry continuously flows between the workpiece and abrasive particles, removing material from the surface. New slurry is replenished, and reaction byproducts are carried away. The newly exposed surface undergoes chemical reactions, leading to a smooth and bright finish through the combined action of the workpiece, abrasives, and chemicals. Achieving the right balance between chemical corrosion and mechanical grinding is key to high-quality results. If chemical effects dominate, surface defects like pitting and orange peel may occur. Conversely, excessive mechanical force can create a damaged layer on the surface.
The automobile aluminum alloy wheel polishing machine uses a flexible mechanical structure to adapt to the complex curved surfaces of the wheel hub. It provides real-time control of grinding force and can polish various sizes, from 12 to 22 inches. The equipment includes 6 polishing stations, one clamping station, and 7 rotation tables. Different polishing heads are available, and the robot can select the appropriate one based on the process. A dust removal system is also integrated, making the operation more environmentally friendly.
The control system supports offline programming, allowing the robot to generate programs directly from 3D drawings of the hub, eliminating the need for manual teaching. The monitoring system detects workpiece displacement and deformation, correcting them in real time. This ensures consistent quality and performance.
In summary, the concept of a robot system goes beyond the physical robot itself. In practice, the system can be customized to meet the specific needs of different stations. Thanks to Nachi's advanced offline programming software and torque-controlled belt machines, the flexibility and capabilities of industrial robots will continue to evolve, driving improvements in application systems.