2411 Roller Fully Automatic Production Line Plan.wps  

Automation Process and Core Equipment Analysis of the Roller Production Line

The roller production line achieves efficient manufacturing—from raw material processing to finished product assembly—through the coordinated operation of multi-process automated equipment. The core processes and equipment are as follows:

I. Pipe Processing Production Line (Core Process for Roller Tubes)

Belt-driven automatic material feeding: Conveys raw material tubes to the designated workstation, ensuring a continuous flow of materials for subsequent processing.

CNC Pipe Cutting Machine for Conveyor Rollers: Utilizing CNC technology to achieve precise, fixed-length cutting, it supports nesting cutting (allowing multiple segments to be cut from a single raw pipe in one go) and ensures accurate control over tube lengths.

Manage and store tubes using a lifting rack: Automatically separate tube materials of different specifications after cutting, enabling categorized storage of materials.

CNC Boring Machine for Roller Tubes: Utilizing patented tube fixture technology to achieve automatic tube centering, reducing runout during machining and ensuring precise end-face machining accuracy for both ends of the tube.

Blowing Chip Removal Component: Utilizing proprietary enterprise technology, it efficiently eliminates chips generated during the machining process, ensuring precision for subsequent operations.

Logistics process: A 3-station + 1-station 90°-rotating robotic arm handles the transfer of pipes between stations, enabling automated flow.

II. Shaft Processing Production Line (Core Process for Roller Shaft)

Automatic shaft feeding to the spindle holder: Automated material loading ensures a continuous flow of materials for shaft-type machining.

CNC Automated Lathe for Roller Shaft: This CNC machine precisely cuts shaft materials to a set length, ensuring high accuracy in shaft dimensions.

V-shaped conveyor line for shafts: Transports shaft materials to the next workstation.

CNC machine tool for beveling and cutting grooves on conveyor roller shafts: Performs precision machining operations such as chamfering the shaft and turning retaining ring grooves, ensuring high accuracy of the shaft end structure.

V-shaped conveyor line/CNC shaft support: Automatically transports shaft materials to subsequent workstations.

Roller shaft automatic deburring machine: Removes burrs from the shaft surface, enhancing surface finish.

V-shaped conveyor line 2: Transports lumber to the final workstation.

Shaft material rack: Stores shaft materials that have been processed.

Logistics process: An automated transfer system, featuring a 2-station + 1-station 90° rotating robotic arm, handles the movement of shaft materials between stations, enabling seamless and automated flow.

3. Bearing Housing Press-Fitting Production Line (Key Process for Roller Assembly)

Bearing housing warehouse, bearing-seal ring warehouse: Stores components such as bearing housings, bearings, and seal rings awaiting assembly.

6-axis robot: Transfer the bearing housing and the bearing-seal assembly separately to Station 4.

Vertical bearing housing press-fitting machine: Completes assembly operations such as pressing and automatic, quantitative oiling of bearings across 4 stations.

Mechanical arm: Remove the pressed bearing housing from the 4-station unit and move it to the next workstation.

Conveyor: Automatically transports and assembles components to the next workstation.

Bearing seat feeding robotic arm: Automatically transports bearing seats, sealing rings, and bearings to the 7-station CNC press-fitting machine for bearing seats.

7 Bearing Housing CNC Press-Fitting Machine: Utilizes a transition fit H8/n8 for press-fitting, with automatic feeding provided by the bearing housing press-fitting production line to complete the final assembly.

4. Roller Assembly and Inspection Production Line (Core Process for Finished Product Manufacturing)

CNC Roller Machine Tool: Precision machining of roller components (equipped with an anti-contamination protective chamber to ensure a controlled processing environment).

Automatic shaft retaining ring press machine 1: Automatically installs the retaining ring, ensuring precise fixation between the shaft and components.

Sealed CNC Press-Fitting Machine: Automatically presses and fits seals, ensuring optimal sealing performance for conveyor rollers.

Roller Rotation Testing Machine: Detects the rotation status of rollers and verifies assembly accuracy.

Roller Fiber Laser Marking Machine: Uses laser marking on rollers to enable product traceability and identification.

Roller Three-Performance Testing Machine: Detects the core performance of rollers, including load-bearing capacity, sealing, and rotational operation, ensuring quality.

Roller rack: Transportation is the responsibility of the production line customer, ensuring finished products are ready for removal from the line.

Logistics process: Seven sets of automated lifting and transferring mechanisms handle the movement of components between workstations, enabling automated flow.

Core Values and Technical Highlights

Highly automated: Utilizing CNC machines, robotic arms, robots, and other equipment, the core processes—including pipe cutting, shaft machining, bearing housing press-fitting, and finished-product inspection—are fully automated, significantly reducing reliance on manual labor.

Precision and Quality Assurance: Patent-invented pipe fixture technology, self-centering pipe design, CNC machining techniques, and more—these innovations control processing accuracy from the very beginning. Additionally, processes such as interference-fit press assembly of bearing housings and automated sealing press fitting ensure superior quality in conveyor roller assembly.

Flexible Production: Multi-station robotic arms and automated feeding/conveying systems enable flexible production of rollers in various specifications, meeting diverse customer needs.

The above process, in collaboration with the equipment, has established a fully automated production chain for conveyor rollers—from raw materials to finished products, thereby achieving a dual enhancement in both efficiency and quality.