Product Introduction: BCNAP-I Type Roller CNC Automated Production Line

I. R&D Background and Industry Position

The BCNAP-I type roller CNC automated production line was independently developed by our company’s R&D center over a period of four years. Its core technologies include four specialized CNC automated machining centers, 18 proprietary processes, three patented technologies, and 31 patent applications currently under review. It represents a benchmark for technological innovation in the roller manufacturing field.

The research and development results have been shared at national industry annual conferences held in Guilin, Tai'an, Haikou, and other cities, receiving high recognition from experts. A technology novelty search report has confirmed that these results are domestically leading. The spin-forming process patented roller produced by our company boasts processing accuracy and technological standards that rank among the best in the industry. Key performance indicators—such as radial runout and axial play—are 1/2 to 1/5 of the values specified in the MT821—2006 standard, precisely meeting the requirements for high-speed, high-capacity belt conveyors under the “Twelfth Five-Year Plan.”

II. Core Advantages: A Triple Breakthrough in Efficiency, Precision, and Intelligence

1. Automation and Efficiency: Reshaping the Production Paradigm

Full-process automation—from raw materials to CNC machining, spray painting and drying, CNC press-fitting, online inspection, and finished-product packaging—achieves “unmanned” collaboration, making this the most highly automated production line in the industry.

Production Capacity and Efficiency: With a team of 5 workers per shift, the monthly output reaches 1,000 units (under a three-shift system, annual production capacity is 1.1 million units). This output is eight times that of conventional equipment, and the efficiency is 16 times higher. A single production line integrates 16 auxiliary devices, including four machining centers, one spray-coating line, two robotic arms, and other equipment, achieving "high productivity" through "reduced manpower."

2. High Precision and Quality: Technological Innovation Shapes Excellence

Roller shaft machining: CNC technology ensures that the finished shaft achieves an accuracy of ±0.02 mm. CNC positioning enhances the axial symmetry between the roller shell and the shaft, exceeding industry standards in precision.

Roller skin processing: A new rust removal and roundness correction step has been added, reducing the radial runout of the roller’s outer diameter to 0.15 (3 to 5 times better than the standard). The bearing housing is joined to the roller skin using a spin-forming process, which features low energy consumption, environmental friendliness, and advanced technology.

Spraying and Anti-Corrosion: The semi-automatic, vertical internal sandblasting machine for roller tube shells (patent) solves the challenge of sandblasting the inner walls of steel pipes longer than 6 meters. The horizontal, instant-curing internal spraying machine (patent) overcomes technical hurdles in spraying the inner walls of steel pipes, thereby extending the service life of rollers.

3. Intelligence and Energy Efficiency: Technology Empowers Cost Reduction and Efficiency Enhancement

Remote Control: Supports both on-site and remote control. The remote end can perform “human-machine interaction” tasks such as control, monitoring, surveillance, programming, and production statistics, enabling more flexible management.

Automated painting: Automatic spraying reduces labor intensity, and waste heat generated during cooling is recovered for space heating and domestic hot water, thereby saving energy. A 5-axis robotic arm, working in conjunction with a suspended conveyor chain, automatically loads and unloads roller skins. A self-clamping specialized lifting fixture (patent) ensures precise handling and transfer.

Shaft-Insertion Automation: An automated shaft-insertion method (patented) replaces manual labor. The length-to-diameter ratio i is 0.0022 (calculation formula: i = (D - d)/L, where D is the hole diameter in mm, d is the shaft diameter in mm, and L is the shaft length in mm). This is an industry first, saving labor costs and increasing efficiency by a factor of eight.

4. Press-fitting and Inspection: Quality Shines in the Details

Dual-head rotary 6-station CNC press-fitting: Solves the “difficult-to-automate” assembly processes for internal and external seals, bearings, elastic retaining rings, and other components, simultaneously enhancing both process accuracy and reliability.

Online Inspection: The automatic roller inspection machine covers various inspections including axiality, resistance, and axial runout, ensuring quality control throughout the entire process.

3. System Architecture: Modular Collaboration, Flexible Adaptation to Requirements

The production line is centered around system integration software and equipment, including two UX-001 roller skin machining centers, one UX-101 roller shaft machining center, one UX-201 roller assembly press center, and an automated coating line. It is complemented by two 5-axis robotic arms, three conveyor lines, deburring machines, online inspection machines, material hoppers, and finished-product bins—among other auxiliary equipment. Thanks to its modular design, the line not only ensures full-process automation but also allows for flexible adaptation to varying production capacity requirements.

IV. Process Flow: The “Smart Transformation” from Raw Material to Finished Product

Pre-treatment of roller skin blanks: vertical internal wall sandblasting → horizontal internal wall spraying—laying the foundation for subsequent processing.

Automatic roller skin processing: Raw material storage → Servo-driven fixed-length feeding → Cutting → Boring at both ends → Internal bore deburring → Spin-forming the bearing housing → Outer diameter machining → Robotic transfer to conveyor.

Automatic roller-coating: Conveyor → Quantity buffer → Robotic arm feeds to spray booth → Automatic spraying → Tunnel oven heating/cooling → Robotic arm removes parts from the line → Transfers to shaft-insertion assembly machine.

Automatic processing of roller shafts: Raw material storage → Servo-driven fixed-length feeding → Six-station rotary dual-head machining (cutting, milling grooves, milling flat surfaces, drilling center holes, turning groove chamfers, drilling holes, deburring) → Transfer to the shaft-insertion and assembly machine.

Automatic shaft-insertion assembly: Roller shell/shaft buffer → Robotic arm assembly → Transfer to the press-fitting center.

Automatic roller press-fitting: Servo positioning → Press-fitting inner and outer seals, bearings, lubrication, and retaining rings → Robotic arm delivers to conveyor.

Automatic Inspection and Packing: The inspection machine performs tests (including runout, resistance, and axial play) → Qualified products are packed.

V. Economic Benefits and Industry Value

Costs and Benefits: Each roller reduces production costs by 5 yuan, while offering a quality premium of over 10 yuan. With an annual output of 1.1 million rollers per production line, the annual revenue increase exceeds 16.5 million yuan, yielding significant economic benefits.

Industry Leadership: Reconstructing the roller production logic with “high precision, high efficiency, and intelligentization” to provide reliable supporting components for high-end equipment such as high-speed, large-capacity belt conveyors, thereby driving the industry’s upgrade from “traditional manufacturing” to “intelligent manufacturing.”

The BCNAP-I type roller CNC automated production line, centered on technological innovation, achieves a triple breakthrough in “efficiency, precision, and intelligence.” It serves as a benchmark solution for “reducing costs, improving quality, and enhancing efficiency” in the roller manufacturing sector, helping enterprises seize the technological high ground in their industry.