For idler rollers, a core component widely used in mining, ports, and logistics, a highly efficient, intelligent, and environmentally friendly fully automated painting line solution is not only a guarantee for improving product corrosion resistance and appearance quality, but also a strategic choice for enterprises to reduce costs, increase efficiency, and achieve green manufacturing.

I. Core Solution: Deeply Integrated Automated Painting System

The fully automated idler roller painting line proposed in this solution is an intelligent integrated system highly matched with the fully automated idler roller production line. It achieves fully unmanned operation from polishing and rust removal to painting, drying, and unloading/palletizing. It can operate independently or be centrally controlled and linked with upstream production lines, flexibly adapting to various production rhythms.

The core components and processes of the system are as follows:

Feeding and Pre-treatment: Qualified rollers produced from the fully automated idler roller production line are polished by an idler roller polishing CNC feeder, effectively removing slight rust and grease from the roller surface, laying a good foundation for the painting process.

Intelligent Transfer and Suspension: The gantry robot precisely grasps the polished idler rollers and transfers them to the fully automatic follow-up feeding machine. The core of this process is the patented conveyor chain lifting device (invention patent technology). Its locking mechanism automatically and reliably locks the idler roller shaft into place, ensuring no risk of the roller falling off during high-speed follow-up conveying. This completely solves the industry problem of automatic idler roller loading and unloading, a first in China.

Environmentally Friendly Precision Spraying: The idler rollers enter the CNC fully automatic spraying room along with the lifting device. High-voltage electrostatic automatic spraying technology is used here, with environmentally friendly water-based industrial coatings (especially water-based acrylic coatings) as the spraying medium. This coating has advantages such as good film-forming effect, excellent color retention, fast drying, and convenient application, and has been widely used in airport terminals, high-end equipment manufacturing, and other fields, conforming to the trend of green manufacturing. The spraying room is equipped with a vacuum bag filter dust collector to ensure a clean working environment. High-efficiency curing and off-line processing: After spraying, the idler rollers enter a closed hot air drying room for rapid curing. They are then automatically picked up by a fully automatic follow-up unloading machine, and then precisely gripped and automatically stacked by a gantry robot 2, finally placed on an idler roller stacking trolley for storage or the next stage.

Technical parameters and performance advantages:

High-efficiency cycle time: The standard production cycle time is 40 seconds/piece. The system can achieve stepless speed adjustment within a ±10% range through a frequency converter and drive device, flexibly responding to different production capacity requirements.

Wide compatibility: It can handle DTⅡ type structure idler rollers with roller diameters of φ89 to φ219, lengths of 280-2000mm, shaft diameters of φ20 to φ40, and a maximum weight of 80Kg, demonstrating excellent adaptability.

Reliable assurance: Patented lifting tools and full-process CNC management ensure process stability and product consistency, greatly saving labor costs and reducing safety risks. This solution can be seamlessly integrated with the fully automated CNC idler roller production line provided by Gudebaofeng to form a complete intelligent production line from core component processing to surface treatment, realizing data exchange and centralized management and control, laying a solid foundation for customers to build an intensive and flexible "smart factory".