Analysis of Automated Processes and Core Equipment in Idler Roller Production Lines The idler roller production line achieves efficient production from raw mat
Analysis of Automated Processes and Core Equipment in Idler Roller Production Lines
The idler roller production line achieves efficient production from raw material processing to finished product assembly through the collaborative operation of multiple automated processes. The core processes and equipment are as follows:
I. Pipe Processing Production Line (Core Process for Idler Rollers)
* **Automatic Belt Pipe Feeding:** Conveys raw material pipes to designated workstations, providing a continuous material flow for subsequent processing.
* **Idler Roller Pipe Cutting CNC Machine Tool:** Utilizes CNC technology for fixed-length cutting, supporting nesting cutting (multiple sections cut from a single raw material pipe at once), precisely controlling pipe length.
* **Pipe Sorting and Storage Self-Lifting Rack:** Automatically separates pipes of different specifications after nesting cutting, enabling classified storage of materials.
* **Idler Roller Pipe CNC Boring Machine Tool:** Achieves pipe self-centering through patented pipe clamping technology, reducing runout during processing and ensuring the precision of the pipe end stops.
* **Chip Blowing Component:** Employs proprietary technology to efficiently remove chips generated during processing, ensuring accuracy in subsequent processes. Logistics: A 3-station + 1-station 90° rotating robotic arm completes the handling of pipe materials between stations, achieving automated flow.
II. Shaft Processing Production Line (Core Process of Idler Roller Shafts)
Automatic Shaft Feeder: Automatically feeds materials, providing a continuous material flow for shaft processing.
Automatic CNC Cutting Machine for Idler Roller Shafts: CNC cuts shaft materials to a fixed length, ensuring shaft length accuracy.
V-Shaped Conveyor Line: Conveys shaft materials to subsequent stations.
CNC Chamfering and Grooving Machine for Idler Roller Shafts: Performs precision machining such as chamfering and circlip groove machining on the shafts, ensuring the structural accuracy of the shaft ends.
V-Shaped Conveyor Line/CNC Shaft Feeder: Automatedly conveys shaft materials to subsequent stations.
Automatic Deburring Machine for Idler Roller Shafts: Removes burrs from the shaft surface, improving surface finish.
V-Shaped Conveyor Line 2: Conveys shaft materials to the final station. **Shaft Material Rack:** Stores processed shaft materials.
**Logistics:** A 2-station + 1-station 90° rotating robot handles the transport of shaft materials between stations, achieving automated flow.
**III. Bearing Housing Press-fit Production Line (Core Process of Idler Roller Assembly)**
**Bearing Housing Storage, Bearing-Sealer Storage:** Stores bearing housings, bearings, seals, and other components to be assembled.
**6-Joint Robot:** Transports bearing housings and bearing-sealer components to station 4.
**Vertical Bearing Housing Press-fitting Machine:** Performs pressing and automatic quantitative oiling of bearings at station 4.
**Robot:** Removes the pressed bearing housing from station 4 and transports it to the next station.
**Conveyor:** Automates the transport of assembled components to the next station.
**Bearing Housing Feeding Robot:** Automatically transports bearing housings, seals, and bearings to the 7-bearing housing CNC press-fitting machine. 7. Bearing Housing CNC Press-fitting Machine: Employs H8/n8 transition fit press-fitting, automatically fed by the bearing housing press-fitting production line to complete final assembly.
IV. Idler Roller Assembly and Inspection Production Line (Core Process for Finished Products)
* Idler Roller CNC Machine Tool: Performs precision machining on idler roller assemblies (with a pollution-proof protective room to ensure a safe processing environment).
* Automatic Shaft Retaining Ring Press-fitting Machine 1: Automatically installs retaining rings, ensuring the fixing accuracy of the shaft and assembly.
* Seal CNC Press-fitting Machine Tool: Automatically press-fits seals, ensuring the sealing performance of the idler roller.
* Idler Roller Rotation and Assembly Machine: Detects the rotation status of the idler roller, verifying assembly accuracy.
* Idler Roller Fiber Laser Marking Machine: Performs laser marking on the idler roller, enabling product traceability and identification.
* Idler Roller Three-Performance Testing Machine: Tests the core performance of the idler roller, including load-bearing capacity, sealing, and rotation, ensuring quality.
**Roller Frame:** Transferred by the production line orderer to complete the finished product rollout.
**Logistics:** Seven sets of automatic lifting and translation mechanisms handle the transport of components between workstations, achieving automated flow.
**Core Value and Technological Highlights:**
**High Automation:** Utilizing CNC machine tools, robotic arms, and robots, core processes such as pipe cutting, shaft processing, bearing housing press-fitting, and finished product inspection are automated, significantly reducing reliance on manual labor.
**Precision and Quality Assurance:** Patented pipe clamp technology, self-centering pipe design, and CNC machining technology control processing precision from the source; processes such as bearing housing transition fit press-fitting and automatic sealing press-fitting ensure the quality of idler roller assembly.
**Flexible Production:** Multi-station robotic arms and automatic feeding/conveyor systems support flexible production of idler rollers of different specifications, meeting diverse needs.
These processes and equipment work together to construct a fully automated production chain for idler rollers from raw materials to finished products, achieving a dual improvement in efficiency and quality.
