In the industrial manufacturing sector, idlers serve as the core components of conveyor systems, and the quality of their surface treatment directly impacts equipment lifespan and operational efficiency. A certain enterprise has developed a fully automated idler coating production line that integrates eight intelligent workstations, enabling seamless collaboration to minimize uncontrollable factors typically associated with manual spraying—and achieving zero-defect output of up to 2,000 idlers per day. This article will delve into the innovative features and core technologies underlying this advanced process.

I. Fully Automated Production Line: The Intelligent Transformation from Raw Materials to Finished Products

1. Roller Fully Automatic Production Line: Smart Launch

The production line begins with a fully automated roller conveyor system, precisely controlled by a CNC system that manages raw material delivery, cutting, and shaping. This stage features a modular design, enabling rapid switching between different roller specifications—and boosting production efficiency by 300% compared to traditional manual operations.

2. Polished CNC Feeder: A Revolution in Surface Treatment

Enter the roller polishing CNC feeder, where the rollers, driven by a high-speed rotating polishing wheel and an intelligent pressure control system, achieve:

Surface rust removal rate ≥ 99%

Oil residue level ≤ 0.1 mg/cm²

The Ra roughness value remains stable below 0.8 μm.

This device is equipped with an AI-powered visual inspection system that provides real-time feedback on polishing quality, eliminating errors caused by manual judgment.

  II. Intelligent Handling Systems: The Precision-Driven, High-Efficiency Logistics Revolution

3. Truss Robot Arm 1: Millisecond-Level Gripping

The truss-type robotic arm No. 1 features a six-axis linkage design, achieved through a laser positioning system:

Grabbing accuracy: ±0.05 mm

Single capture time ≤ 1.2 seconds

Supports 24-hour continuous operation

The collaboration between the robotic arm and the fully automatic follow-up feeding system boosts material handling efficiency by 40%.

4. Fully Automatic Tracking Feeder: The Smart Technology of the Patented Lifting Device

This segment's patented lifting device employs follow-along suspension technology, achieved through:

Dynamic Balance Control System

Wireless Transmission Positioning Module

Non-slip cushioning design

Achieve zero-damage transportation of rollers on the conveyor chain, extending the lifeline of lifting tools by up to three times compared to traditional products.

  III. Core Spraying Process: The Perfect Balance of Environmental Protection and Quality

5. CNC Fully Automatic Spray Booth: The Precision Art of High-Voltage Electrostatics

The high-voltage electrostatic automatic spraying system operates via:

A 60kV high-voltage electric field charges the coating particles.

Rotary spray gun achieves 360° uniform coverage

Intelligent Flow Control (error ±0.5 ml/min)

Equipped with a suction-type baghouse dust collection system (filtration efficiency ≥99.9%), the coating utilization rate is increased to 85%, while VOC emissions are reduced by more than 30% below the national standard limits.

6. Enclosed Hot-Air Drying Chamber for Spray Coating Lines: The Science of Temperature Control

This segment utilizes:

Three-stage temperature control system (preheating - constant temperature - cooling)

Infrared Thermometer (Accuracy ±1°C)

Negative-pressure ventilation design

Ensure the coating cures uniformly at 60–80°C, reducing the drying time to one-third of that required by conventional processes.

  IV. Intelligent Finishing System: Automation from Material Feeding to Palletizing

7. Fully Automatic Tracking Feeder: Precise Picking

The cutting machine passes through:

Visual Recognition System Localization

Pneumatic Gripper with Flexible Grasping

Automatic Weighing and Inspection

Achieve zero-damage removal of rollers, with an automatic sorting accuracy rate for defective products reaching 99.8%.

8. Truss Robot Arm 2: The Wisdom of Palletizing

The truss robot arm 2 utilizes:

3D Vision Positioning System

Dynamic Path Planning Algorithm

Collision Avoidance Warning System

Achieving intelligent palletizing with roller conveyors, capable of stacking up to 12 layers in a single operation—resulting in palletizing efficiency that is 5 times higher than manual methods.

V. The Value of Process Innovation: A Comprehensive Breakthrough from Efficiency to Quality

This production line is achieved through:

Full-process automation (reducing manual intervention by 90%)

Intelligent Quality Monitoring (Defect Rate Reduced to 0.02%)

Eco-friendly process upgrade (energy consumption reduced by 35%)

Achieving a 42% reduction in processing costs for single-roller components, while exceeding an annual production capacity of 500,000 units, has positioned us as an industry leader.