Polishing Industry Pain Points
Deburring is a key post-processing step for aluminum alloy die castings, and it is also a difficult, highly labor-dependent, and time-consuming process. Currently, die casting plant customers generally face multiple challenges in manual deburring: low work efficiency, poor workpiece quality consistency, plus difficulty recruiting workers and high labor costs, resulting in low overall production efficiency and persistently high total costs.
Industrial Robot Polishing
Automation upgrade solution:
To break through the bottleneck of manual deburring, industrial robot automated polishing systems are becoming the direction of industry innovation. Compared with traditional manual methods, its core advantages are reflected in three dimensions:
Leap in efficiency and capacity
Robots can work continuously 24 hours a day; a single unit is equivalent to 3-5 skilled workers.
A case from a well-known domestic die casting enterprise shows that after introducing robots, single-piece processing time was reduced by 62% and daily capacity increased by 200%.
Quality consistency and precision control
Through force control sensing and vision positioning technology, robots can achieve ±0.1mm repeat positioning accuracy, eliminating individual differences in manual operations.
Tests on aluminum alloy parts at an automaker showed that automated polishing reduced the defect rate from 8.7% in manual operation to 0.9%.
Structural optimization of total cost
Cost Dimension Manual Method Robot Solution Direct labor cost ~¥15,000/month per person (incl. training) Equipment depreciation ~¥3,000/month Quality loss cost 5-8% of output value Controlled within 1% Long-term marginal cost Continuously rising Investment recovered in 3 years
Technology extension value:
Flexible production capability: through rapid changeover programs, the same workstation can handle 20+ different types of castings, adapting to the small-batch customization trend.
Closed-loop data management: polishing parameters are uploaded to the MES system in real time, realizing digital process traceability and providing decision support for lean production.
Key Advantage Comparison
Industrial robots not only solve the efficiency and quality pain points of manual mode, but also restructure the production value chain through a standardized operation system. Although the initial investment is higher than manual labor (about ¥400,000-800,000/unit), within a two-year operating cycle, total cost reversal can be achieved through efficiency gains (capacity increase), quality dividends (reduced defect rate), and hidden cost reduction (injury risk/management losses), providing sustainable competitive support for die casting enterprises.
INEXBOT Polishing Types
It can automatically change grinding wheels for multiple types of polishing, and the robot automatically performs multiple polishing passes in different directions. The polishing types available are as follows:
• Polishing of welding spatter.
• Polishing of surface dents and scratches.
• Grinding flat of weld reinforcement.
• Grinding flat of machining allowance.
• Polishing of long and large welds.
• Removal of edges and burrs.
Combined with external axis equipment such as positioners, large sheet metal parts can be polished to ensure a smooth and flat polishing result.
Combined with offline programming, compliant polishing of complex curved surface workpieces can be achieved.
Combined with line-scan laser tracking technology, the following automated polishing programming can be achieved:
2-point positioning line.
3-point/4-point positioning user coordinate system.
Polishing Usage Scenarios
Scenario 1
Scenario description:
Polish a straight line;
Polishing count 1, polishing angle 0 degrees (angle of the current taught point), start polishing;
After polishing, wait for the continue-polishing signal.
Scenario 2
Scenario description: polish a straight line, polish 4 passes at the taught position, 2 passes offset +15 degrees in the positive direction, and 2 passes offset -15 degrees in the negative direction.
Scenario 3
Scenario description: the polishing head has worn 1mm and parameters need to be adjusted.
Setup steps:
Go to Process/Polishing Process/Polishing Parameters, select the corresponding process number, and click Modify;
Fill in tool wear compensation as 1 and click Save;
After setup is complete, run the program.
Scenario 4
Polish a straight line, polish 4 passes at the taught position, and 2 passes offset +15 degrees in the positive direction with laser position search.
Download Links
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