Fully Automated Idler Roller Coating Line Product Introduction

I. Our fully automated idler roller coating line directly addresses the core pain points of traditional manual coating: low efficiency, uneven coating quality, high environmental pressure, and inability to efficiently integrate with automated production lines. It provides a smart coating solution that is "cycle-matched, fully automated, and highly environmentally friendly," seamlessly connecting with upstream assembly to achieve a closed loop from "production" to "finishing."

II. Four Major Advantages

🤝 Seamless Cycle Matching, Production Line Integration: The cycle time is consistent with the fully automated idler roller production line, with a standard cycle time of 40 seconds (±10% adjustable). It supports independent or centralized control operation, achieving a smooth connection between assembly and coating.

🤖 Fully Unmanned, Automated Loading and Palletizing: Integrating a gantry robot, patented lifting devices, and a follow-up loading and unloading machine, it achieves a "fully automated cycle" from gripping, spraying, drying to palletizing, completely eliminating manual handling.

🎨 High-Quality Environmentally Friendly Coating

Utilizing "high-voltage electrostatic automatic spraying" of water-based industrial coatings (such as acrylic esters), combined with "baghouse dust collection" and closed-loop hot air drying, ensuring excellent coating quality while meeting environmental requirements.

⚙️ Patented Lifting Fixture, Reliable Clamping
Equipped with a domestically pioneering patented conveyor chain lifting fixture, automatically clamping the idler roller shaft groove flat, ensuring the idler roller remains stable and does not fall off during spraying, solving the technical challenges of automatic loading and unloading.

III. Technical Specifications

IV. Usage Scenario Description
Imagine a traditional spray painting workshop: Freshly assembled idler rollers are transported to the spray booth by workers using forklifts or handcarts. Operators, wearing heavy protective suits, manually spray paint through the pervasive paint mist. This is inefficient, results in uneven coating thickness, produces a pungent odor, puts immense pressure on environmental treatment, and carries a high risk of workpiece damage during handling.

Now, please switch to the intelligent workshop equipped with this fully automated spraying line: the idler rollers, assembled from the upstream fully automated production line, enter a finishing assembly line. First, they undergo surface cleaning by a polishing machine. Then, a gantry robot, like a nimble arm, picks them up and smoothly delivers them to a fully automated follow-up feeding machine. At this point, the core patented lifting device automatically starts, its locking blocks precisely engaging the grooves on the idler roller shaft, firmly securing the workpiece. The lifting device, suspending the idler roller, enters the fully enclosed CNC spraying room, where multiple high-voltage electrostatic spray guns automatically start according to a preset program, evenly spraying environmentally friendly water-based paint, while a bag filter dust collection system efficiently collects the paint mist. The sprayed idler rollers then enter the hot air drying room, where they rapidly cure into a film at a controlled temperature. Finally, another gantry robot removes them and neatly stacks them on an idler roller stacking trolley. The entire process is unmanned, with a stable cycle time of approximately 40 seconds, perfectly synchronized with the upstream production line. The workshop air is fresh, producing finished idler rollers with uniform coating and top-quality output.

V. Social Proof

Patent Technology Barrier: The core patented conveyor chain lifting device is a domestically pioneering invention patent, solving the industry's technical bottleneck of achieving reliable automatic loading and unloading in the spraying process, forming a solid technological moat.

Verifiable Efficiency Data: A standard cycle time of 40 seconds (adjustable) is clearly set and precisely matched with the upstream production line's 42-second cycle time, ensuring maximum efficiency of the entire line. The data is specific and verifiable.

High-End Process and Material Application: The water-based industrial coatings used are explicitly mentioned for application in high-end fields such as airport terminals and equipment manufacturing. The water-based acrylic coatings possess advantages such as excellent film-forming effect and outstanding color retention, indirectly proving that the coating quality produced by this spraying line reaches an advanced level in the industry.

Systematic Environmental Solution: The entire line integrates "baghouse dust collection technology" and the use of water-based coatings, providing a complete environmental solution from process collection to source replacement, meeting current stringent environmental regulations.

VI. Comparative Advantages

Automation Level vs. Human Labor Dependence

This painting line: Achieves full automation from workpiece transfer, loading and unloading, spraying, drying to palletizing, replacing all heavy manual operations with robotic arms and patented lifting devices.

Traditional Manual/Semi-Automatic Spraying: Highly dependent on manual handling, hanging, hand-held spraying, and unloading, resulting in high labor intensity, low efficiency, and a significant impact on worker health due to the working environment.

Production Cycle Time and Line Synergy

This painting line: Designed with a standard cycle time of 40 seconds, it can be "matched and connected" with upstream fully automated production lines, supporting independent or centralized control operation, achieving seamless integration of assembly and painting, forming a highly efficient continuous flow.

Independent spraying equipment: Often mismatched with the cycle times of upstream and downstream processes, creating production bottlenecks, requiring significant work-in-process buffering and scheduling, disrupting production flow and overall efficiency.

Coating quality consistency and environmental friendliness

This spraying line: Employs "high-voltage electrostatic automatic spraying," ensuring stable process parameters and coating uniformity; uses water-based industrial coatings in conjunction with baghouse dust collection, reducing VOC emissions at the source, offering significant environmental advantages, and providing superior coating performance (film formation, color retention).

Traditional air spraying/manual operation: Coating thickness and uniformity are greatly affected by worker skill and condition; often uses solvent-based coatings, resulting in high VOC emissions, significant environmental pressure, and a poor working environment.

VII. FAQ

Q: How does this spraying line integrate with the preceding idler roller production line? Is manual handling required?

A: This spraying line is specifically designed for integration with the fully automated idler roller production line. The assembled idler rollers are automatically picked up by a gantry robot and automatically loaded onto the production line via a fully automatic follow-up feeder and a patented lifting device, eliminating the need for manual handling throughout the process. The production cycles of both are matched (40 seconds for this line, approximately 42 seconds for the previous line), allowing for seamless integration and continuous automated production.

Q: What is the patented lifting device? How is it ensured that the idler rollers do not fall off during spraying?

A: The patented conveyor chain lifting device is the core invention patent of this line. Its working principle is that the locking mechanism on the lifting device automatically locks the idler roller shaft into the groove when it enters. This reliable design ensures that the idler rollers will not fall off even when suspended at high altitudes and during conveyor chain operation, safely solving the key technical challenge of automatic loading and unloading.

Q: What are the benefits of using water-based paint and baghouse dust collection? A: Water-based industrial coatings (such as water-based acrylics) are environmentally friendly coatings with low VOC content, minimal odor, fast drying, and excellent film-forming and color retention properties, enhancing product appearance and weather resistance. Baghouse dust collectors effectively collect overspray mist particles generated during spraying, purifying workshop air and reducing pollution emissions. Together, these two components constitute a green and environmentally friendly coating solution.

Q: Can the production cycle be adjusted? Can it adapt to different specifications of idler rollers?

A: Yes, it can be adjusted. The standard cycle time for the spraying line is 40 seconds, but it can be adjusted within a standard range of ±10% using a frequency converter and drive unit to meet different production rhythm requirements. This line is designed for various specifications of DTⅡ type idler rollers with diameters of φ89-219mm, lengths of 280-2000mm, and shaft diameters of φ20-40mm. By adjusting the hangers and program parameters, it can adapt to product changes within a certain range.