Six Axis Robotic Polishing Machine PLC Control For Cast Aluminum Products
Six Axis Robot Aluminum Polishing Machine
,Cast Aluminum Robotic Polishing Machine
,Cast Aluminum Product Polishing Machine
The only robotic polishing system engineered from the ground up for the full spectrum of cast aluminum components — from engine housings and pump bodies to structural brackets and enclosures. Achieve Ra ≤0.05 μm mirror finish or functional Ra ≤0.4 μm in a single automated cell.
Cast aluminum presents a unique combination of challenges that defeat generic polishing machines:
| Challenge | Why It's Hard | Our Solution |
|---|---|---|
| Dimensional variation | Die-cast & gravity-cast parts vary ±0.3-0.8 mm batch to batch | Force-controlled end-effector auto-compensates in real time |
| Complex 3D contours | Curved flanges, internal cavities, boss radii, fillets | 6-axis reach + compliant spindle covers any surface angle |
| Soft, gummy material | Aluminum loads abrasives fast, smears under excess pressure | Adaptive pressure control prevents over-polishing and loading |
| Porosity & inclusion | Sub-surface pores revealed by heavy polishing = scrap | Gentle, consistent force reveals fewer pores vs. manual buffing |
| Multi-surface parts | Sealing faces, OD bosses, cosmetic covers all on one casting | Multi-step program polishes all zones in one fixturing |
Built on a heavy-duty industrial robot platform with a purpose-designed compliant polishing spindle, the LR-POLISH CA Series delivers repeatable, process-validated surface finishing across the widest range of cast aluminum geometries in the industry. One cell. One operator. Unlimited part programs.
Full 6-axis articulation allows the polishing tool to approach every surface of a complex casting at the optimal angle — eliminating the "shadow zones" that defeat 3- and 4-axis gantry polishers.
- Wrist rotation: ±360°
- Reach envelope: up to 2,010 mm
- Repeatability: ±0.02 mm
The proprietary compliant spindle unit measures and adjusts contact force 1,000* per second.
- Force range: 1-30 N (user-defined per zone)
- Resolution: ±0.2 N
- Result: uniform material removal regardless of casting warpage, porosity, or dimensional scatter
Define up to 12 sequential polishing stages within a single part program:
| Stage | Tool | Target |
|---|---|---|
| Flash / parting line removal | Rotary carbide burr | Dimensional |
| Pre-polish | 320-600 grit flap disc | Ra ≤0.8 μm |
| Intermediate polish | Sisal buff + cutting compound | Ra ≤0.2 μm |
| Fine polish | Cotton buff + fine compound | Ra ≤0.1 μm |
| Mirror finish | Flannel buff + mirror compound | Ra ≤0.05 μm |
Import casting CAD (STEP / IGES / STL) → generate polishing paths in simulation → deploy to robot. No teach pendants. No production downtime for new model introduction.
- New part program: < 4 hours (engineer) / < 10 min changeover (operator)
- Unlimited program storage
- Simulation video included with every new part program
Optional integrated contact profilometer checks Ra on critical surfaces after each cycle. Auto pass/fail with SPC data logging — full traceability per part.
Robot polishes Part A while operator loads/unloads Part B. Effective robot utilization: >92%. No idle time between cycles.
- Fully enclosed polishing cell (IP54 enclosure)
- Integrated HEPA-grade aluminum dust extraction
- Compliant with ATEX Zone 22 / OSHA 1910.94 aluminum dust standards
- Operator exposure: <0.5 mg/m³ (well below TLV-TWA)
| Parameter | LR-POLISH CA-14 | LR-POLISH CA-20 |
|---|---|---|
| Robot axes | 6 | 6 |
| Max reach | 1,440 mm | 2,010 mm |
| Robot payload | 14 kg | 20 kg |
| Repeatability | ±0.02 mm | ±0.02 mm |
| Spindle speed | 500-12,000 RPM | 500-12,000 RPM |
| Force control range | 1-25 N | 1-30 N |
| Force resolution | ±0.2 N | ±0.2 N |
| Part size (max) | 500 * 400 * 300 mm | 800 * 600 * 400 mm |
| Part weight (max) | 25 kg | 50 kg |
| Surface finish achievable | Ra 0.05-0.8 μm | Ra 0.05-0.8 μm |
| Cycle time (std. housing) | 90-240 sec | 120-360 sec |
| Cell footprint | 3,000 * 2,600 mm | 3,800 * 3,200 mm |
| Power supply | 380 V / 3-phase / 50 Hz | 380 V / 3-phase / 50 Hz |
| Control system | PLC + 12" HMI | PLC + 15" HMI |
| Communication | PROFINET / EtherCAT / Modbus TCP | PROFINET / EtherCAT / Modbus TCP |
| Certifications | CE / ISO 9001:2015 | CE / ISO 9001:2015 |
The LR-POLISH CA Series is production-validated across the following cast aluminum part families:
- Engine oil cooler housings & filter seats
- Transmission & gearbox housings
- EV motor end shields & inverter housings
- Steering knuckles & suspension brackets
- Throttle body & intake manifold flanges
- Hydraulic pump bodies & valve blocks
- Pneumatic cylinder end caps
- Compressor housings & scroll covers
- Gearbox end covers & bearing housings
- Sheet metal + die-cast hybrid enclosures
- Power supply & converter housings
- Industrial control cabinet panels
- Heat sink bodies (cosmetic + functional finish)
- Structural brackets & mounting plates
- Flanged pipe fittings & manifolds
- Impeller casings & volute housings
Reference: mid-volume automotive casting line, 600 parts/day, 2 shifts, 250 days/year
| Metric | Manual Polishing Line | LR-POLISH CA Series |
|---|---|---|
| Headcount | 10 operators | 2 operators |
| Throughput consistency (Cpk) | ~0.85 | ≥1.67 |
| Rework / scrap rate | 12% | < 1.5% |
| Annual labor cost | $300,000 | $60,000 |
| Annual consumable cost | $35,000 | $22,000 |
| Annual quality cost (rework) | $48,000 | < $6,000 |
| Total annual savings | -- | ≈ $295,000 |
| Investment payback | -- | ≈ 12-18 months |
Import casting CAD → Generate OLP path → Simulate & validate → Deploy in < 10 min
Operator places part on dual-station rotary fixture (Station B loads while A polishes)
6-axis robot runs multi-stage program: deburr → pre-polish → fine polish → mirror finish
Inline Ra probe checks critical surfaces auto pass / fail logged
Finished part exits with Ra cert & SPC data stamp
Next part enters Station A; zero robot idle time
Every LR-POLISH CA cell is delivered with full documentation:
- ✅ FAT Report — Factory Acceptance Test with Ra measurements on your actual casting
- ✅ OLP Simulation Video — polishing path preview for your specific part
- ✅ CE Declaration of Conformity — EU Machinery Directive 2006/42/EC
- ✅ ISO 9001:2015 Certificate — certified manufacturing & QMS
- ✅ SPC Data Package — process capability report (Cpk) from FAT
- ✅ 12-Month Warranty — full mechanical & electrical coverage
- ✅ Operator Training — on-site commissioning + video library
Critical spare parts stocked in regional warehouses:
- 🇩🇪 Europe (Germany)
- 🇺🇸 North America (Michigan)
- 🇹🇭 Southeast Asia (Thailand)
- 🇨🇳 China (Shanghai)
Cloud-connected HMI enables our engineers to diagnose and resolve >70% of issues remotely — without a site visit.
- Europe & North America: 48-hour on-site SLA
- Asia-Pacific: 72-hour on-site SLA
- Worldwide remote support: 24/7
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