LH-Gantry Extractor and Sprayer Robot

1. Product Introduction (Key Points)

• All-in-one automation solution combining precision part extraction and uniform spraying for die casting production lines.

• Features advanced vision guidance and three-dimensional motion control for complex manufacturing tasks.

• Handles payloads up to 50kg vertically with ±0.01mm repeat positioning accuracy for consistent quality.

• Seamlessly integrates with existing die casting equipment through flexible communication protocols.

• Reduces manual intervention in high-temperature environments, enhancing workplace safety.

• Configurable working envelope to accommodate various production line layouts and part sizes.

2. Product Description

3. Product Features and Highlights

• Dual-Function Excellence: Combines two critical production steps—part extraction and surface spraying—into a single automated process, eliminating transfer time between stations and reducing production cycle time by up to 30%.

• Superior Precision: Boasts ±0.01mm repeat positioning accuracy across all axes, ensuring consistent part placement and uniform coating thickness (30-50μm) that manual operations simply can't match. This precision reduces coating waste by 22% on average.

• Intelligent Vision System: Equipped with a high-resolution CCD camera and advanced image processing that identifies part variations and adjusts spraying parameters in real-time, ensuring optimal coverage even for complex geometries.

• High-Speed Performance: Achieves movement speeds up to 1000mm/s with smooth acceleration/deceleration control, completing extraction and spraying cycles in as little as 8 seconds for small to medium parts.

• Robust Construction: Features hardened steel rails, heat-resistant components, and IP54-rated protection against dust and liquids, ensuring reliable operation in harsh die casting environments with a mean time between failures exceeding 10,000 hours.

• Flexible Programming: Offers both teach pendant and offline programming options with an intuitive interface that allows operators to create new spraying patterns in less than 30 minutes, even for complex part geometries.

4. Technical Parameters

5. Application Scenarios

• Automotive Die Casting: Perfect for handling aluminum engine components, providing consistent release agent application before casting and protective coating after extraction. A leading auto parts manufacturer increased production yield by 18% after implementation.

• Consumer Electronics: Ideal for processing zinc alloy phone frames and laptop casings, ensuring uniform primer application for subsequent painting processes. The vision system easily accommodates minor design variations in product generations.

• Industrial Hardware: Efficiently handles small to medium-sized cast metal parts like valve bodies and connectors, applying corrosion-resistant coatings with precise thickness control.

• Appliance Manufacturing: Streamlines production of cast aluminum parts for refrigeration and HVAC systems, where consistent surface treatment is essential for thermal efficiency and aesthetics.

• Aerospace Components: Meets the stringent precision requirements for processing lightweight alloy parts, where coating uniformity directly impacts performance and safety.

6. Core Advantages

• Cost Reduction: By integrating two operations into one automated process, manufacturers typically reduce labor costs by 40-60% while cutting material waste by 20-25% through precise coating application.

• Quality Improvement: The ±0.01mm positioning accuracy and vision-guided spraying reduce part defects by an average of 35%, significantly lowering scrap rates and rework expenses.

• Production Efficiency: Faster cycle times (8-15 seconds per part) and 24/7 operation capability increase overall throughput by 25-40% compared to manual operations.

• Workplace Safety: Eliminates worker exposure to high temperatures, sharp edges, and chemical coatings, reducing workplace injuries by up to 90% in treated areas.

• Process Consistency: Automated operation ensures every part receives identical treatment, reducing variation and improving overall product quality and reliability.

• Data Integration: Equipped with industrial communication protocols to connect with MES systems, providing valuable production data and enabling predictive maintenance.

7. Usage & Maintenance Guide

• Setup & Operation:

1. Position the robot in alignment with die casting machines using the integrated laser alignment tool.

2. Calibrate the vision system using the provided calibration plate and reference parts.

3. Program extraction paths and spraying parameters via the touchscreen interface or import offline programs.

4. Conduct test runs with sample parts to verify positioning accuracy and coating quality.

5. Integrate with production line control systems using the standard Modbus or Ethernet/IP protocols.

• Preventive Maintenance:

1. Daily: Inspect rail surfaces for debris and clean with recommended lubricant; check fluid levels in spray system.

2. Weekly: Verify vision system calibration; inspect cable connections for tightness; test emergency stop functions.

3. Monthly: Lubricate all moving components; check spray nozzle for wear; calibrate pressure regulators.

4. Quarterly: Perform full system accuracy check; inspect drive belts for tension and wear; clean ventilation systems.

5. Annually: Complete comprehensive system inspection by certified technicians; replace wear items per maintenance schedule.

8. After-Sales Service

• Warranty Coverage: 2-year warranty on mechanical components, 1-year warranty on electronic parts, and 6-month warranty on wear items like spray nozzles.

• Technical Support: 24/7 online support via phone, email, and video conference with response times guaranteed under 2 hours.

• Maintenance Contracts: Flexible plans ranging from basic preventive maintenance to full-service agreements with guaranteed response times.

• Spare Parts Supply: Global network of parts warehouses ensuring 24-hour delivery of critical components and 48-hour delivery for all other parts.

• Training Programs: On-site and online training courses for operators, maintenance personnel, and programmers, with certification options.

• Performance Monitoring: Optional remote diagnostics system that provides real-time performance data and alerts for proactive maintenance.

9. Why Choose Us

• Specialized Expertise: With 15 years focused exclusively on die casting automation, our engineering team understands the unique challenges of this industry and designs solutions specifically for these environments.

• Proven Performance: Installed in over 500 production facilities worldwide, with an average customer retention rate of 92% for repeat purchases.

• Customization Capability: Our modular design approach allows tailored solutions for specific production requirements, with lead times averaging just 4-6 weeks for custom configurations.

• Technology Leadership: Continuous R&D investments ensure our robots incorporate the latest advancements in vision systems, motion control, and materials science.

• Total Cost of Ownership: Our systems typically achieve full ROI within 12-18 months through labor savings, quality improvements, and increased throughput.

• Global Presence: With regional offices in Asia, Europe, and North America, we provide local support wherever your production facilities are located.

10. FAQ

• Q1: How long does it take to integrate the robot into an existing production line?
  A: Typical integration takes 3-5 days for standard installations. This includes physical setup, system calibration, programming basic operations, and operator training. Complex installations with multiple machine integration may take 1-2 weeks. Our technical team works with your production schedule to minimize downtime during transition.
• Q2: Can the robot handle different part sizes and shapes without extensive reprogramming?
  A: Yes, the advanced vision system allows the robot to recognize variations in part geometry within programmed parameters. For significant design changes, our intuitive programming interface enables quick parameter adjustments, typically requiring less than 30 minutes for experienced operators to configure new part programs.
• Q3: How does the robot handle variations in part positioning from the die casting machine?
  A: The integrated vision system compensates for positional variations up to ±5mm by automatically adjusting the extraction path in real-time. This flexibility eliminates the need for precise mechanical alignment between machines and accommodates normal wear in die casting equipment.
• Q4: What safety features are included to protect workers and equipment?
  A: The robot includes multiple safety layers: guarded work envelope with light curtains, emergency stop buttons at multiple locations, speed monitoring with automatic slowdown near operators, thermal sensors to detect temperatures, and software limits on movement ranges. All safety features comply with ISO 13849-1 and CE standards.