Industry Pain Points: Deburring Challenges

Deburring is a critical yet challenging post-processing step for aluminum alloy die-cast parts, characterized by high labor dependency and time consumption. Die-casting factories currently face multiple challenges in manual deburring processes:

• Low operational efficiency

• Inconsistent workpiece quality

• Recruitment difficulties

• Rising labor costs

These factors collectively lead to reduced production efficiency and increased comprehensive costs.

Industrial Robot Automation: The Upgrade Solution

To break through manual deburring bottlenecks, robotic automated polishing systems are emerging as an industry revolution direction. Compared to traditional manual methods, core advantages manifest in three dimensions:

1. Efficiency & Production Capacity Leap

• 24/7 continuous operation

• One robotic unit equates to 3-5 skilled workers

• Case Study: A domestic die-casting enterprise achieved 62% reduction in single-piece processing time and 200% daily capacity increase after robot implementation.

2. Quality Consistency & Precision Control

• ±0.1mm repeat positioning accuracy via force control sensing and visual positioning technology
• Defect Reduction: Automotive aluminum component tests showed defect rates dropping from 8.7% (manual) to 0.9% (automated)

3. Comprehensive Cost Optimization

Technological Extension Value

• Flexible Production: Single workstation handles 20+ different castings through rapid mold-changing programs, adapting to small-batch customization trends.

• Data-Driven Management: Real-time grinding parameters uploaded to MES systems enable digital process traceability, supporting lean manufacturing decisions.

Key Advantage Comparison

Industrial robots not only resolve efficiency and quality pain points in manual operations but also reconstruct production value chains through standardized workflows. Despite higher initial investment (~￥400,000-800,000/unit), comprehensive cost inversion is achievable within a 2-year operational cycle through:

• Efficiency gains (200% capacity increase)

• Quality dividends (7.8% defect reduction)

• Hidden cost reduction (workplace injury risks/management overhead)

iNexBot Polishing Capabilities

• Multi-process Support: Automatic wheel changes for various polishing operations:
  • Welding spatter removal

  • Surface scratch/collision repair

  • Weld seam leveling

  • Machining allowance smoothing

  • Long/seam Polishing

  • Edge/burr removal

• Enhanced Configurations:
  ✓ External axes (positioners) for large sheet metal components

  ✓ Offline programming for complex curved surface finishing

  ✓ Laser tracking for automated programming:

  • 2-point positioning for straight lines

  • 3/4-point user coordinate system calibration

Application Scenarios

Scenario 1

Straight line polishing

• 1 pass at 0° angle (current teaching point)

• Await continuation signal post-operation

Scenario 2

Multi-angle straight line polishing

• 4 passes at teaching position

• 2 passes at +15° offset

• 2 passes at -15° offset

Scenario 3

Tool wear compensation

1. Navigate > Process > Polishing Parameters

2. Select process ID > Modify

3. Input 1mm wear compensation > Save

4. Resume operation

Scenario 4

Hybrid laser-guided Polishing

• 4 passes at teaching position

• 2 passes at +15° offset

• 2 laser-positioned passes

Resource Access

Click here to download Polishing-related technical materials