product key technologies
By the end of 2025, we have built a stable mass production line with an annual output of 100,000 sets, and delivered more than 120,000 sets of various joint module parts, becoming the core supplier of joint module structural parts for this customer.
This is not a simple equipment investment, but a systematic upgrade from "being able to make samples" to "stable mass production".
The first batch of samples of the customer covers 7 key parts such as planetary frame, rotor frame, shell, output flange, stator seat, front end cover, and feedback tube, and undertakes the core functions of structural support, power transmission, and sensing feedback. At that time, there was no mature mass production standard in the industry, and we tackled tough problems with high-precision processing standards
|
parts |
Accuracy requirements |
Core difficulties |
|
Planetary shelf |
The position of the planetary hole ≤ 0.015mm |
The cumulative error of porous system is difficult to control |
|
Rotor rack |
Coaxiality ≤ 0.008mm |
1.8mm thin wall, clamping is easy to deform |
|
Shell |
The coaxiality of the bearing hole ≤ 0.01mm |
The length-to-diameter ratio is 8:1 deep hole, and it is easy to vibrate |
|
Output flange |
End runout ≤ 0.005mm |
Large diameter thin walls, flatness is difficult to guarantee |
|
stator constellation |
The roundness of the inner hole ≤ 0.004mm |
Thin-walled sleeves are easy to lose their roundness when clamped |
|
Front end cover |
The position of the threaded hole ≤ 0.02mm |
Multi-feature composite processing |
|
Feedback tube |
Inner diameter tolerance ±0.005mm |
Slender deep holes, difficult to measure and stabiliz |
Entering small-batch trial production, we encountered typical pain points in the mass production of precision parts:
Efficiency bottleneck
The traditional processing of 12 precision holes of the planetary frame takes 14 minutes per piece, and the monthly production capacity is less than 2,000 pieces; The thin walls of the rotor frame need to be cut at low speed, 10 minutes per piece, and the production capacity cannot match the customer's climbing.
Consistency challenges
Dimensional drift due to tool wear and equipment thermal deformation in mass production. The Cpk of the planetary hole position of the first batch of 300 pieces is only 0.89, and there is a risk of about 8% deviation. The feedback tube reamer has a lifespan of about 80 pieces, and the size fluctuates by ±0.008mm after tool change, which is close to the tolerance limit.
Supply chain fluctuations
Shell 6061-T6 aluminum alloy bar delivery time up to55 days; The thickness deviation of the outsourced anodized film was ±8μm, which resulted in a 100-piece case size out-of-size with a yield of only 91%.
We completed the full link upgrade of process, quality, digitalization, and supply chain in 18 months to achieve stable mass production.
Our Products
Planetary shelf
Process:five-axis + compound tool + four-station fixture rough turning benchmark→ five-axis one-time clamping finishing, internal cold drilling and hinge compound tool one-time forming; The four-station rotary table is synchronously processed with 4 pieces.
Results: The processing time was 14 minutes →8 minutes, the monthly production capacity was 2000→6000 pieces, and the planetary hole position degree was 1.38.
Rotor rack
Process:low-stressclamping + four-axis linkageelastic sleeve + end face pressing, clamping force 800N→350N, reduce deformation; Four-axis clamping completes multi-faceted machining in one go.
Results:The coaxiality pass rate was 82%→97%, the time was 10→7 minutes, and the Cpk was 1.35.
Feedback tube
Process:Fine boring + rolling + tool life controlRough boring→ precision boring→ rolling composite processing, stable size; The reamer life iscompulsorily replaced according to 60 piecesto avoid wear drift.
Results: The inner diameter was 1.48, and the difference in tool change size was ±0.008→±0.002mm.
Housing/Output Flange
Special scheme anti-vibrationboring rod + five-axis positioning for shape control and vibration control shell, eliminating vibrating knife pattern,Cpk 1.41;
The output flange is uniformly clamped with hydraul, and the whole process is completed in one clamping,Cpk 1.52.
Quick changeover
The zero point positioning systemfixture can be replaced in 45 minutes → 5 minutes, and the multi-variety production can be changed in 3.5 hours →45 minutes, which is suitable for multi-model and small-batch mixing.
WithZeiss coordinatesas the core, establish a closed loopof first inspection→ inspection→ and final inspection
First article: Mass production can only be achieved if the full-size test is qualified
Inspection: Critical dimensions are detected every 2 hours, with automatic warning of Cpk<1.33
Final inspection: 100% full inspection of key dimensions, traceable report
Key dimensions after mass production stabilization:
|
parts |
Key features: |
Target Cpk |
Actual Cpk |
|
Planetary shelf |
Planetary hole position |
≥1.33 |
1.38 |
|
Rotor rack |
Coaxiality |
≥1.33 |
1.35 |
|
shell |
The bearing bore is coaxial |
≥1.33 |
1.41 |
|
Output flange |
End face runout |
≥1.33 |
1.52 |
|
stator constellation |
The roundness of the inner hole |
≥1.33 |
1.44 |
|
Feedback tube |
Inner diameter |
≥1.33 |
1.48 |
Deploy an MES system to:
※ Real-time monitoring of work orders, tools, and equipment, and automatic locking of tools after the deadline;
※A single piece scanning code can trace raw materials, equipment, personnel, and testing data;
*Quality traceability is reduced from 2–4 hours →30 seconds, and the tool life is reduced to 0.
※2.5 monthssafety stockfor key materials, long-term contract with suppliers to lock production capacity;
※Outsourcing oxidation plant two-party audit + batch inspection + in-plant sampling inspection;
※Result: The oxidation yield was 91%→98.5%,and the risk of raw material supply interruption was basically eliminated.
|
stage |
time |
Monthly capacity /set |
Comprehensive yield |
Lead time |
|
Prototype period |
January–March |
Trial production |
-- |
42 days |
|
Small batches |
April–September |
1800 |
76% |
32 days |
|
Climbing period |
October–18 months |
5200 |
88% |
22 days |
|
Stability Mass production |
From 19 October |
8500 |
94% |
21 days |
Key Milestones:
※Month 12: Monthly production capacity exceeded 5,000 sets, and the yield rate exceeded 90% for the first time
※Month 18: Monthly production capacity reaches 8,000 sets,annual production capacity exceeds 100,000 sets
※Month 24: The delivery time is 21 days, which is 16% faster than the industry average
By the end of 2025, a total of 120,000 sets of joint module parts have been delivered, and customers cover the head humanoid robot companies, with core real indicators:
Mass production PPM:within 320 (industry excellent level).
Critical dimension Cpk:Stable ≥ 1.33
Delivery on-time rate:98.5%
Lead time:21 days (industry average 25–30 days).
Customer complaints:0 batch quality problems
Customer's annual evaluation evaluation:"The supplier has complete engineering capabilities from prototypes to large-scale mass production, stable accuracy and reliable delivery, and is the core partner of our joint module supply chain."
Written at the end
From 10 samples to 120,000 units for mass production, from 42 days to 21 days, from 76% to 94% yield. We deeply understand thatsamples rely on craftsmanship, and mass production depends on the system. From the laboratory to the market, the core requirements of the supply chain are: steady, fast, and low-cost.
We have:
※Imported turning / milling / three, four and five axes / special process processing clusters, suitable for high-precision thin walls / deep holes / porous / special-shaped profiles / special material parts;
※Zeiss three-coordinate full-scale testing, the whole process quality closed-loop;
※MES digital control can be traced and expanded;
*Stable delivery capacity of 100,000 units per year.
Focus:core precision parts of humanoid robots. We are willing to work with partners to go from samples to mass production, from the laboratory to thousands of households.
