Intelligent Robotic Aluminum Polishing Machine For Headlight lens
Intelligent Robotic Aluminum Polishing Machine
,Robotic Polishing Machine for Headlight Lens
,Headlight Lens Aluminum Polishing Machine
| Industry Pain Points | Our Solutions |
|---|---|
| Manual polishing pressure variance causes haze bands and light-scatter defects that fail OEM photometric tests | Constant-force end-effector (±0.5 N) ensures uniform abrasive contact across the full curved lens surface, every cycle |
| CNC polishing leaves tool marks on double-curvature zones near mounting flanges — high scrap on complex freeform geometry | Adaptive 6-axis path planning auto-compensates for lens profile deviation; real-time profilometer feedback updates tool path mid-cycle |
| Skilled polisher shortage: 2-3 years to train; turnover disrupts Tier-1 headlamp line throughput | Recipe-driven setup — new part programs load in under 10 minutes; one operator supervises up to 4 cells |
Integrated 6-DOF force/torque sensor maintains polishing normal force within ±0.5 N throughout the full lens contour — eliminating over-polishing on thin flange edges and under-polishing in concave wells.
3D vision scan + offline CAD import generates collision-free spiral/raster hybrid tool paths. Mid-run profilometer feedback triggers path offset correction when surface roughness deviates beyond Rz ±0.3 µm setpoint.
Automated abrasive magazine cycles through P400 → P800 → P1500 → polishing compound in a single cell — no manual changeover, no cross-contamination between stages. Consumable wear is monitored by spindle torque trending.
Every lens receives a QR-linked data record: cycle time, force profile, roughness trend, and pass/fail flag. IATF 16949-compatible data export for OEM production control plans.
Part profile captured, deviation map generated vs. CAD nominal
P400 belt removes casting oxide layers and gate marks
P800-P1500 stages reduce Rz to ≤ 1.0 µm
Compound + felt buff achieves Ra ≤ 0.05 µm
Gloss meter + profilometer scan; auto-sort pass/reject
| Robot Axes | 6-axis articulated arm (payload 10-20 kg) |
| Positional Repeatability | ± 0.02 mm |
| Surface Roughness (Final) | Ra ≤ 0.05 µm (mirror grade) |
| Polishing Force Range | 2 - 30 N (programmable) |
| Force Control Accuracy | ± 0.5 N |
| Spindle Speed | 500 - 6,000 RPM (servo-controlled) |
| Max Part Envelope | 600 * 400 * 250 mm (custom available) |
| Abrasive Stages | Auto-magazine, up to 6 stations |
| Cycle Time (typical lens) | 4 - 8 min (part-dependent) |
| Vision System | Structured-light 3D scanner, 0.01 mm resolution |
| Communication | EtherCAT / PROFINET / OPC-UA |
| Certifications | CE, ISO 9001, IATF 16949 data-ready |
| Power Supply | 380V / 3-phase / 50-60 Hz |
| Cell Footprint | 2.4 m * 1.8 m |
- Headlight Lens Housing (die-cast aluminum, freeform)
- Reflector Bowl (mirror-grade parabolic surface)
- Projector Lens Barrel (bi-function & matrix LED)
- EV / NEV Headlamp Housing (Tier-1 supply chain)
- Adaptive DRL Frame (complex geometry, thin wall)
- Custom OEM Parts (program upload in < 10 min)
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