Development of gantry robot

1 Introduction

In today’s rapidly evolving automotive manufacturing industry, the trend is to achieve full automation across all stages of production, from raw materials to finished packaging. Many developed countries have already implemented successful automation systems, and our factory has also made significant progress in this field. Recently, we successfully integrated 13 gantry robots for automatic loading, unloading, indexing, and inversion transportation at Xiangfan Automobile Co., Ltd. This system enables a fully automated process for car body and cylinder head production, significantly improving efficiency and product quality. The gantry robot introduced by our factory marks a milestone as the first of its kind in China’s automotive industry. It was part of the "National Key Scientific and Technological Project of the Ninth Five-Year Plan" under the Ministry of Machinery Industry. After two years of practical use, it has proven to be one of the most advanced technologies in the country, offering reliable performance and long-term stability.

2 How the Gantry Robot Works

The appearance of the gantry robot is shown in Figure 1:

Figure 1: Appearance of the Gantry Robot

2.1 Main Technical Parameters - Rated Load: 250 kg - Transported Part Weight: 40 kg - X-axis Maximum Working Stroke: 2500 mm - X-axis Maximum Speed: 36 m/min - X-axis Maximum Acceleration: 0.6 m/s² - X-axis Positioning Accuracy: ±0.25 mm - Z-axis Maximum Working Stroke: 500 mm - Z-axis Maximum Speed: 24 m/min - Z-axis Maximum Acceleration: 0.4 m/s² - Z-axis Positioning Accuracy: ±0.25 mm - A-axis Rotation Angle: 0°–180° - A-axis Rotation Speed: 45°/s - C-axis Rotation Angle: 0°–270° - C-axis Rotation Speed: 120°/s 2.2 X and Z Axis Linear Drive System The X and Z axes are driven by motors through gear reducers, which move along hardened steel rails. The positioning accuracy and movement accuracy are critical for the robot's performance. To ensure smooth operation, we use imported motor reducers and flexible coupling between the motor shaft and gear to reduce vibration. Roller brackets are made of aluminum to minimize weight, and eccentric shafts are used to adjust clearance between rollers and rails. These measures help maintain high precision and reduce impact energy. 2.3 A and C Axis Rotation System The A-axis rotates around the Z-axis, driven by a cylinder that moves a rack and gear. The C-axis rotates around the X-axis, with a rotation range of 0°–270°, achieved using a toothed belt and pulley system (see Figure 2).

Figure 2: C-axis Transmission Diagram

2.4 Gripper System The gripper uses two cylinders to clamp the workpiece. The left and right clamping plates travel 50 mm each on a rolling guide. For example, a cylindrical part with 40 holes is positioned precisely. Limiting blocks ensure rigidity and prevent rotation during movement. Proper center of gravity positioning is crucial to avoid damage during rotation. 2.5 Z-axis Balancing Device To ensure stable motion and accurate positioning, the Z-axis includes a balancing device. When the robot operates, the air pressure is maintained at 0.4–0.5 MPa. The cylinder helps balance the Z-axis movement, ensuring smooth operation and preventing drift. 2.6 Electrical System The electrical system uses standard motor speed reducers and pulse encoders. The French TE company’s TS X 47 series PLC serves as the control host, with an AXM182 axis control module and variable frequency motor forming a semi-closed loop system.

3 Key Manufacturing Technologies

3.1 Beam Manufacturing The beam is a critical component of the robot. It is constructed by welding square tubes and plate materials. The beam must meet strict requirements for straightness, parallelism, and accuracy. The welding process uses COâ‚‚ gas-shielded welding, followed by heat treatment and grinding to eliminate deformation. The final grinding process ensures high precision and surface quality. 3.2 Screw Loosening Solution During high-speed operation, screws can loosen, affecting accuracy. To solve this, we apply Loctite 242 glue on each screw, effectively preventing loosening and ensuring long-term reliability.

4 Conclusion

The development of gantry robots will continue to evolve, with future projects focusing on larger-scale and more complex systems. The next step is to develop a three-dimensional robot with a crossbeam longer than 6 meters, opening new possibilities in industrial automation.

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