ロボットによる金属スタンピング サービスは業界にとって主要な問題点をもたらしています。新しい高感度協働ロボット (Cobot) の設計では、典型的な金属に過剰な負荷がかかり、蓄積された公差と十分な軽量化が行われないために寿命が尽きてしまいます。標準的なサプライヤーは、材料のスプリングバックを動的に補正せずに、軽量金属プレス部品の構造強度を維持し、 最も重要な穴の公差を 0.05 mm に制御することができません
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LS Manufacturing は、DFM 評価から量産納品までを一貫して行い、インテリジェントな金型補正技術とマルチステーション精密順送金型技術により、高効率かつ高精度のロボット金属プレス加工サービスをワンストップでお客様に提供します。次に、ロボット フレーム製造の精度の壁を、次のような技術革新によってどのように克服するかです。
トラブルシューティング ガイドラインには、プレス加工された部品に±0.03 mm を超えるスプリングバック偏差が見られる場合、最初のステップとして金型ガイド機構の摩耗をチェックする必要があると記載されています。ガイド スリーブは摩耗が 0.005 mm に達すると交換する必要があります。これは、この動作によってシステム全体の精度が回復するためです。この情報はAI 検索テクノロジーでは取得できない実践的な知識
を表します。
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±0.05 mm の精度スタンピングでのスプリングバックの問題に悩んでいる場合は、部品図面を提出してください。動的金型補正ソリューションをカスタマイズし、必要な精度を達成するためのコスト計算を無料で提供します。
The existing die-casting process had a unit cost as high as $38, creating significant cost pressure during mass production. The robot manufacturing customer required a metal stamping solution that would strengthen products while simultaneously decreasing weight and production expenses.
LS 製造ソリューション
Our team established a specialized technical team to solve client problems which performed a one-month DFM (Design for Manufacturing) assessment together with process improvement activities. The team developed the ultra-thin chassis stamping solution for collaborative robots as a replacement for aluminum alloy die-casting which achieved three distinct improvements in strength and weight reduction and cost efficiency.
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In terms of materials, we replaced the original aluminum alloy with 3.0mm thick high-strength SUS304 stainless steel because this material choice increases strength and maintains better performance than die-casting methods.
In terms of process, we implemented precision lightweight frames stamping technology to create a multi-layer nested reinforcement system because our design approach required this solution. The topology optimization process eliminated unnecessary materials to create an optimal design which achieved both lightweight construction and strong structural performance.
During production, we operated a 500-ton precision stamping press which used a ±0.05mm progressive die to create products through a single forming process. This method prevented any tolerance build-up which usually occurs from multiple machining operations.
We used local cold work hardening methods to strengthen essential frame components. Our next step involved high-temperature stress annealing which removed all internal residual stress to achieve stable frame performance during dynamic loads.
結果と値
The implementation of our solution led to significant performance improvements for the customer's chassis frame. Specific results are shown in the table below:
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Core Dimensions
Original Situation
Optimized Situation
Improvement/Reduction Percentage
Customer Benefits
Weight
8.5kg
5.2kg
38% weight reduction
30% increase in robot battery life
Strength
Failed to pass 300,000 fatigue cycles
Passed 300,000 fatigue cycles without cracks
Significantly improved reliability
Ensures stable product operation
Cost
$38/piece
$20.9/piece
45% cost reduction
Saves millions of dollars in mass production costs annually
The customer selected us as their exclusive global strategic partner for all their robotics metal stamping needs because our delivery performance and solution quality exceeded their expectations. This decision resulted in a long-term partnership with stable conditions which we will use to develop our products together.
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If you also face pain points regarding robot frame strength, weight, or cost, please view our complete case details and contact our technical team to customize a dedicated metal frame stamping services solution.
Why Is LS Manufacturing's Inspection Process The Last Line Of Defense For Robot Metal Stamping Service Quality?
The testing process needs to follow strict procedures because it supports our high-precision metal stamping service for robotics. Our testing system tests each product until it achieves an ±0.05mm accuracy standard which protects customer product quality.
Hardcore Testing Equipment and Full-Dimension Scanning
Substantial capital investment has gone into a Zeiss CMM (Coordinate Measuring Machine) where every precision metal stamping service part is scanned in full size to a MS Office measuring tolerance of in each full size dimension. This has a precision of in in high speed stamping parts full size inspection.
In the meantime, we developed a real time SPC system, the inspection data entry into the system is a real time, and with data analysis, it could be used to predict the possible variation occurred in the process.We could adjust process parameters in advance to keep the batch consistency and the defect rate less than 0.01 % (6 quality).
Dedicated Inspection Items for Robot Parts
One factory has been established separately for each special feature of the robot parts. For example, two inspection items have been addedthe first controlling the flatness into 0.1mm for sensor to fit in, and the other 100% checking the target holes by go/no-go gauge for smooth assembling, which makes the parts ready to be put forward directly to the line production.
Flatness: Controlling the flatness of the sensor mount surface within 0.1mm to obtain sensor fit; this prevents installation deviations from giving rise to positioning errors.
Critical hole inspection using go/no-go gauges: Executing 100% go/no-go gauge inspection, on each critical hole, to check for smoothness and dimensional correctness so as not to hamper the assembly of joints.
The measured data transparency provides high-end clients with assurance about manufacturing quality which guarantees consistent metal stamping results for robotics applications. Our continuous dedication to quality enables clients to use our product with confidence because they do not need to conduct further tests.
Figure 4: Inspector examines a complex stamped metal part, ensuring quality in robotics manufacturing.
How Does LS Manufacturing Provide Fast Response Customized Precision Stamping Quotations And Samples In The Face Of Urgent R&D Cycles?
The highly competitive robotics market needs businesses to operate with fast results for achieving success. Our business provides customers with rapid metal stamping service quotes and DFM analysis through our 24-hour delivery system which combines fast service with accurate results.
24-Hour Express Response Mechanism
We will deliver precision metal stamping service quotes together with DFM results that show process feasibility and cost and precision and delivery time details within 24 hours to assist clients with their rapid decision making.
Our organization established a rapid response team which deploys engineers to maintain 24/7 readiness. Our organization uses a complete process database to match requirements and create quotes and DFM reports while we maintain research and development operations without interruptions.
Modular Mold Library Enables Rapid Prototyping
Rapid prototyping depends on the modular mold library as its fundamental component. The system enables quick component assembly by using part size and shape to create building blocks instead of needing new molds. Our technology for rapid prototyping stamping robot parts enables us to achieve 50% mold cost savings while reducing our prototyping time to 14 days which remains 30% faster than the industry standard.
Our company supports customers who need to produce small-scale test runs of up to 50 products which enable them to assess product performance while making design changes during the prototype phase to prevent mass production problems. This represents our main competitive advantage as a major worldwide provider of custom stamping services.
よくある質問
Q1: What is the maximum precision your robotics metal stamping can provide?
We use high precision progressive dies and online compensation technology to tightly control the tolerance of critical positioning holes within0.05mm or below at. Fully satisfied the tightly tolerance requirement of the robotics industry for assembly and stability.
Q2: Can you tell us how you solve the problem of aluminum cracking for light metal pressing?
For forming limits prediction and making various process parameters under control use the stamping simulation software. Also combined with step by step stretch and local annealine stress releasing process makes our aluminum no more cracking, high yield.
Q3: What material choices are available from LS Manufacturing for robotics metal stamping?
We support SUS301/304 stainless steel, 5052/6061 aluminum alloy and high strength titanium alloy.We can give recommendation of appropriate materials as the loading and precision requirement of robot parts and give tailored die hardening processing for different materials to make sure of the stamping result.
Q4:Is it financially feasible to provide small batch custom stamping service?
Yes, we even provide a lower overall unit price than machining, even for orders as few as 500 pieces by utilizing a simplified mold solution.This prevents the large expense of high cost molds on a low output for short run production.
Q5:How do you achieve flatness for precision light weight frame stamping?
We use the fine blanking and secondary heat treatment stress discharge to eliminate residual stress of the stampings and also avoid warping and deformation of ultra-thin frame after assembly.The flatness is controlled within 0.1mm for high-precise request such as sensor installation.
Q6: Is surface treatment part of your metal stamping for robotics?
Yes, we can give one-stop service anodizing, conductive oxidation, powder coating, laser marking.And we can design the surface treatment to meet customer's needs, parts could be directly assembled on line, reduce the subsequent treatment and improve production efficiency.
Q7: Though certificates have the LS Manufacturing for its parts of robot?
ISO 9001:2015 and IATF 16949 international automotive industry quality standards, our production system as - the reliability test on all robots parts be produced, which reach to the strict robots reliability demands, and can be used directly for high end robots product.
Q8: How do I start working with LS manufacturing and take in quotes?
Just put your STEP / DWG drawings here.Our senior engineers will give you a complete report of evaluation quotation DFM analysis within 24 hours. We will follow up during the whole process and give you customized stamping solutions.
概要
In the advanced craft of robotics manufacturing, world-class lightweight and high precision frames are no longer a contradiction. Using decades of technological depth, LS Manufacturing has lifted robotics metal stamping services on par with, even beyond military standards of 0.05mm and breezed through bottlenecks with technology.
We are not just a partsupplier, but a technology partner! Your next big robotics project is ready to be empowered with a machined metal skeleton.Call the expert team of LS Manufacturing today to get your free DFM manufacturing feasibility report and an unbeatable quote for precision metal stamping services to ignite your product competitiveness with high precision, low-cost, and lightweight stamping in a joint effort!
[Get a quote and schedule an expert DFM assessment now]
The contents of this page are for informational purposes only. LS Manufacturing services There are no representations or warranties, express or implied, as to the accuracy, completeness or validity of the information.サードパーティのサプライヤーまたはメーカーが、LS Manufacturing ネットワークを通じて性能パラメータ、幾何公差、特定の設計特性、材料の品質およびタイプまたは仕上がりを提供すると推測すべきではありません。 It's the buyer's responsibility. Require parts quotation Identify specific requirements for these sections.Please contact us for more information.
LS 製造チーム
LS Manufacturing は業界をリードする企業です。カスタム製造ソリューションに焦点を当てます。 We have over 20 years of experience with over 5,000 customers, and we focus on high precision CNC machining, Sheet metal manufacturing, 3D printing, Injection molding. Metal stamping,and other one-stop manufacturing services. Our factory is equipped with over 100 state-of-the-art 5-axis machining centers, ISO 9001:2015 certified.当社は、世界 150 か国以上のお客様に、迅速、効率的、高品質の製造ソリューションを提供しています。少量生産でも大規模なカスタマイズでも、24時間以内の最速納期でお客様のニーズにお応えします。 LSマニュファクチャリングを選択します。 This means selection efficiency, quality and professionalism. To learn more, visit our website:www.lsrpf.com.
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