Case of Robotic Polishing of Door Handles
A well-known hardware manufacturer has long specialized in producing a wide range of door and window hardware accessories. They produce a wide variety of door handles in various styles, including stainless steel and zinc alloy. With growing market demand and increasingly stringent quality control requirements, the manufacturer faced the challenge of improving door handle polishing efficiency and quality consistency. Traditional manual polishing processes limited the number of door handles per worker to a certain number per day. Due to differences in worker skill and fatigue, polishing quality varied widely, resulting in a high defect rate. Furthermore, the large amount of metal dust generated during manual polishing posed a serious threat to worker health and the production environment. To overcome these bottlenecks, the manufacturer decided to introduce advanced automated polishing equipment.
II ：Solution: Collaborative Operation of Automated Metal Polishing Machines and Robots
After in-depth market research and technical evaluation, the manufacturer selected an automated metal polishing system based on a six-axis robot. This system consists of the following key components:
1. High-precision six-axis robot: Featuring high flexibility and precise motion control, it can perform multi-angle, all-around polishing operations according to the complex shape of the door handle using pre-programmed functions.
2. Intelligent automatic metal polishing machine: Equipped with a variety of polishing tools, such as sanding belts and polishing wheels of varying grits, it automatically switches between different polishing tools based on the door handle material and polishing process requirements. The polishing machine utilizes an advanced pressure control system that monitors and adjusts polishing force in real time, ensuring uniform and appropriate pressure on the door handle surface throughout the polishing process, thereby ensuring consistent polishing quality.
3. Automated loading and unloading system: The collaborative operation of a conveyor belt and a robot enables automated loading and unloading of door handles. This automated process significantly reduces manual intervention, improves production efficiency, and reduces the risk of product damage caused by improper operation.
III. Implementation Process
1. Process Planning and Programming: Initially, the technical team conducted a detailed process analysis of the various door handles produced by the manufacturer and developed customized polishing plans based on their various shapes, materials, and polishing requirements. Using professional robotic programming software, they programmed precise motion trajectories for the six-axis robot, ensuring that the robot could precisely control the door handles according to the predetermined path and motions. Furthermore, they optimized various parameters of the automatic metal polishing machine, such as polishing tool speed, polishing pressure, and polishing time, to achieve optimal polishing results.
2. Equipment Installation and Commissioning: The automatic metal polishing machine, six-axis robot, and automated loading and unloading system were installed according to the planned layout. Rigorous mechanical and electrical commissioning was performed until all performance indicators met production requirements.
3. Employee Training and Trial Production: To ensure the smooth commissioning of the new equipment, comprehensive training was provided to relevant operators and maintenance personnel. The training covered equipment operation, routine maintenance, and common troubleshooting.
IV. Application Results
1. Significantly Improved Efficiency: The introduction of automated metal polishing machines and robots has significantly improved door handle polishing efficiency. This has significantly shortened production cycles and met market demand for rapid product delivery. (Subject to further discussion)
2. Stable and Reliable Quality: Because the robots operate strictly according to preset procedures and parameters, they eliminate the subjectivity and volatility inherent in manual operation, significantly improving the quality of door handle polishing.
3. Significantly Reduced Costs: In terms of labor costs, one standard machine can replace three skilled workers. Furthermore, the automated polishing system allows for more precise control of polishing tool usage, reducing consumable waste and lowering consumable costs. Furthermore, the significantly reduced defective rate reduces the additional costs associated with rework. In the long term, the implementation of automated polishing equipment has brought significant cost advantages to the company. (Subject to further discussion)
Improved Work Environment: The automated metal polishing machine is equipped with a comprehensive dust removal system that effectively collects metal dust generated during the polishing process, creating a safer and healthier working environment for employees. At the same time, the operating noise of automated equipment is relatively low, further improving the comfort of the working environment.
V. Summary and Outlook
By introducing a robotic polishing system, this hardware manufacturer successfully automated its door handle polishing process, achieving significant results in improving production efficiency, ensuring product quality, reducing costs, and improving the working environment. This case study fully demonstrates the enormous potential and advantages of automation technology in the hardware processing industry. With the continuous advancement of technology, the performance of automatic metal polishing machines and robots will continue to improve, and their intelligence will further increase. We believe that in the near future, automated polishing technology will be more widely used in the hardware industry, bringing new opportunities and changes to the industry's development.
