Processing of Moving Parts for Humanoid Robots: Three Core Experiences for Batch Delivery of Complex Structures

Last year in the second half of the year, a humanoid robot manufacturer approached us. After the delivery of the first batch of 100 sets of leg motion components, 12% of them experienced assembly interference, causing repeated rectification and delaying the production ramp up cycle for nearly 2 weeks. This type of problem is very common in the mass production stage of robots: the accuracy of the sample stage meets the standard, but the dimensional consistency is poor after transferring to mass production; The processing deformation rate of complex curved surfaces and thin-walled joint parts is high, and repeated rework reduces the utilization rate of low energy.

Robot parts processing is not simply milling according to drawings, it requires matching corresponding mass production process plans for different component usage scenarios in order to balance accuracy, cost, and delivery stability.

Process adaptation schemes for four types of core robot components

The performance requirements for different components of robots vary greatly. Based on over 3 years of industry service experience, we have compiled process selection references for mainstream mass-produced components:

The Three Core Difficulties and Solutions in Robot Parts Processing

Batch accuracy guarantee for complex surface structures

The joint shells of humanoid robot structural components are mostly irregular surfaces, and ordinary three-axis machining requires multiple clamping, which can easily exceed the tolerance requirements of the drawing due to accumulated errors, resulting in large differences in joint rotation smoothness during mass production and a high probability of jamming and abnormal noise after assembly.

Our solution is to use German imported Demage five axis linkage equipment to complete the processing of all five surfaces in one clamping, greatly reducing the cumulative error caused by multiple clamping. Specially developed standardized fixtures for surface features, with stable positioning errors controlled within ± 0.002mm. The dimensional deviation of a single batch of parts of the same model can be stably controlled within 1/3 of the drawing tolerance, meeting the consistency requirements for joint batch assembly.

Batch deformation control of thin-walled parts

The wall thickness of dexterous hand components and lightweight arm rods is usually only 1.5-2mm. During the machining process of five axis precision parts, they are easily deformed due to stress, and after being placed for a period of time, the shape and position tolerances may exceed the allowable range, seriously affecting the batch qualification rate. Our process plan is:

1. Add a low-temperature stress relief process after rough machining, and hold at 120 ℃ for 4 hours to release more than 70% of residual stress;

2. Precision machining adopts layered milling, with the final machining allowance controlled at 0.15~0.2mm to reduce residual cutting stress;

3. Extract 5% of the parts from each batch and store them for 3 days before conducting tolerance verification to ensure batch size stability.

Through this process, the batch delivery qualification rate of our thin-walled robot parts processing has remained stable at over 98%.

Delivery efficiency guarantee for medium to large-scale mass production

During the ramp up stage of robot mass production, the monthly demand for a single part can reach thousands of pieces. The structural differences between different parts are significant, and frequent changes can easily prolong the delivery cycle. Shenzhen robot parts processing service provider Huiwen Zhizao's 10000 square meter factory is equipped with 150+processing equipment, including 16 five axis machining centers, using a flexible production scheduling system. Conventional simple parts can be shipped in 3-7 days, and complex structural parts can be delivered in 5-10 days.

The workshop implements 24-hour production in two shifts, and once urgently produced 500 sets of robot joint shell processing orders for customers. The entire process from raw materials to finished products was delivered in 3 days, meeting the customer's demand for mass production ramp up.

Whole process quality control standards

In response to the high reliability requirements for robot parts processing, we have established a three-level inspection system:

First piece inspection: After the first piece processing of each component is completed, a full-size inspection is carried out using the German imported Zeiss three coordinate system to confirm compliance with the drawing requirements before starting mass production.

Process inspection: Take 1 out of every 20 pieces for retesting of key dimensions to avoid batch errors caused by tool wear;

Factory inspection: 100% inspection of key installation surfaces and matching dimensions of all delivered parts, accompanied by batch inspection reports for shipment;

As a national high-tech enterprise and specialized new enterprise, we have passed ISO9001 and IATF16949 quality management system certification. All processes comply with the system requirements, with traceable quality and stable processing accuracy of ± 0.005mm.

As a full industry chain service provider specializing in the field of robotics, Huiwen Zhizao has the ability to integrate design, manufacturing, and assembly. It is a professional ODM service provider in the field of robotics and has served multiple technology innovation enterprises and research institutions such as Huawei, Xinsong, Xiaomi Ecological Chain, and the Chinese Academy of Sciences. It has accumulated rich experience in mass production processes for humanoid robot structural components, collaborative robots, and bionic robot parts processing. If you have any needs, whether it is small to medium batch trial production or large-scale production, we can provide drawing consultation and match you with the best process and cost solutions.